CN113163854B

CN113163854B - Tubular element with threads for use with aerosol-generating articles

Info

Publication number: CN113163854B
Application number: CN201980077455.4A
Authority: CN
Inventors: G·坎皮特利
Original assignee: Philip Morris Products SA
Current assignee: Philip Morris Products SA
Priority date: 2018-12-17
Filing date: 2019-12-16
Publication date: 2024-03-19
Anticipated expiration: 2039-12-16
Also published as: WO2020127111A3; US20220046979A1; KR20210104029A; CN113163854A; JP2022511111A; WO2020127111A2; EP3897236A2; BR112021009143A2

Abstract

A tubular element 500 comprising a wire 125 loaded with a gel, said gel 124 comprising an active agent, for use with an aerosol-generating article 100, preferably for use with an aerosol-generating device 200. The various active agents may preferably be released from the tubular element 500 into the aerosol, generated or released upon heating the tubular element 500.

Description

Tubular element with threads for use with aerosol-generating articles

Technical Field

The present disclosure relates to a tubular element for use with an aerosol-generating article, wherein the tubular element comprises a gel-loaded wire.

Background

Articles comprising nicotine for use with aerosol-generating devices are known. Typically, the article contains a liquid, such as an electronic cigarette liquid (e-liquid), which is heated by the crimped resistive wire to release an aerosol. The manufacture, transportation and storage of such aerosol-generating articles comprising liquid can be problematic and can lead to leakage of the liquid and the contents of the liquid.

It is desirable to provide a tubular element for use in aerosol-generating articles and devices in which the tubular element has little or no leakage.

It is also desirable to provide a tubular element that includes a flow control system that efficiently delivers aerosol generated from the tubular element when heated by an aerosol-generating device.

Disclosure of Invention

According to the present invention there is provided a tubular element wherein the tubular element comprises a first longitudinal channel and further comprises a wire loaded with a gel, wherein the gel comprises an active agent.

The present invention provides a tubular element comprising a wrapper forming a first longitudinal channel; the tubular element further comprises a plurality of wires loaded with gel; the gel comprises an active agent.

In some embodiments, the tubular element comprises a wrap.

In some embodiments, the tubular element comprises a wrap, wherein the wrap comprises paper.

In some embodiments, the tubular element comprises a wrap forming a first longitudinal channel; wherein the wrapper comprises paper.

In particular embodiments, there is a single thread loaded with gel. However, in alternative embodiments, there are multiple wires loaded with gel. Each gel-loaded strand may have the same gel or different gels.

In a specific embodiment, in combination with other features, the tubular element comprises a wire loaded with gel, preferably with the same gel. Alternatively, in other specific embodiments, the tubular element comprises a different gel. In a specific embodiment, the tubular element comprises a gel loaded wire, wherein two different wires loaded with gel are loaded with different gels. In particular embodiments, the tubular element comprises more than one gel.

In combination with other features, the tubular element includes a wrap.

In particular embodiments, in combination with other features, the tubular element comprises a susceptor adjacent to at least one gel-loaded wire. The susceptor may be thin and elongated. Preferably, the susceptor is positioned longitudinally within the tubular element. Preferably, the susceptor is surrounded by a gel-loaded wire. In an alternative embodiment, the susceptor is positioned between the inner surface of the wrap and the gel-loaded wire. In particular embodiments, the wrap comprises a susceptor. Alternatively or additionally, the susceptor may be in the form of a powder, such as a metal powder. The powder may be in the gel, or in the wrapper, or spaced between the gel and the wrapper, or a combination thereof.

In combination with other features, in a specific embodiment, the tubular element further comprises a second tubular element.

According to the present invention, there is provided a method of manufacturing a tubular element,

the tubular element comprises:

a first longitudinal channel, and the tubular element further comprises a wire loaded with gel; the gel comprises an active agent;

the method comprises the following steps:

-placing a material for the tubular element around the mandrel to form the tubular element;

-dispensing a gel loaded wire from a catheter within the mandrel such that the gel loaded wire is within the tubular element.

The tubular element may be cut to length. Various lengths may be required. The lengths need not be uniform.

In a specific embodiment, the method of manufacturing a tubular element further comprises the further step of: cutting the tubular element.

In a specific embodiment, the method of manufacturing a tubular element further comprises the steps of: the material for the tubular element is extruded around the mandrel to form the tubular element.

In a specific embodiment, the manufacturing method further comprises the steps of: wrapping the tubular element with a wrap.

the tubular element comprises:

forming a wrap of the first longitudinal channel and further comprising a thread loaded with gel; the gel comprises an active agent; and wherein

The method comprises the following steps:

-dispensing the gel-loaded thread onto a web of wrapping material;

-wrapping a web of wrapping material around the gel-loaded wire to form a wrapped composite structure of gel-loaded wire.

In a specific embodiment, the method of manufacturing a tubular element further comprises the steps of: cutting the gel-loaded wire-wrapped composite structure to length.

the tubular element comprises:

-a wrapper;

-a gel loaded thread; the gel comprises an active agent; and

-a second tubular element;

the method comprises the following steps:

-dispensing the gel-loaded wire onto a web of wrapping material and dispensing a second tubular element onto the gel-loaded wire on the web of wrapping material;

-wrapping the web of wrapping material around the gel-loaded wire and the second tubular element to form a wrapped composite structure of gel-loaded wire and the second tubular element.

In a specific embodiment, the manufacturing method further comprises the steps of: cutting the wrapped composite structure of the loading gel wire and the second tubular member to length.

the tubular element comprises:

-a thread; and

-a wrapper; and is also provided with

-further comprising a gel, wherein the gel comprises an active agent;

the method comprises the following steps:

-dispensing threads on a web of wrapping material;

-dispensing a gel onto the thread on the web of wrapping material such that the gel impregnates or coats the thread and the thread is loaded with gel;

wrapping a wrapping material around the gel-loaded wire to form a gel-loaded wire composite structure.

In a specific embodiment, the method of manufacturing a tubular element further comprises the steps of: the composite structure of gel loaded strands is divided into lengths.

According to the present invention, there is provided a method of manufacturing a tubular element for use in an aerosol-generating article,

the tubular element comprises:

-a wrapper;

-a second tubular element extending along the length of the tubular element;

-loading a thread extending along the hollow tubular element with a gel between the second tubular elements, wherein an additive is dispensed in the gel; and

a wrap around the gel-loaded wire and the hollow tubular element,

the method comprises the following steps:

-extruding material for a hollow tubular element through a forming die and around a mandrel, the mandrel forming a hollow core in the hollow tubular element;

-coextruding gel-loaded strands from a catheter in the forming die and around the hollow tubular element to form a composite core;

-placing the composite core along a web of wrapping material;

-wrapping the wrapping material around the composite core to form a wrapped composite structure.

In a specific embodiment, the method of manufacturing a tubular element further comprises the steps of: the composite structure is divided into lengths to form tubular elements of a desired length.

In a specific embodiment, the method of manufacturing a tubular element further comprises the steps of: a plurality of threads are dispensed.

According to the present invention there is provided a tubular element comprising a first longitudinal channel and further comprising a porous medium loaded with gel; the gel comprises an active agent. In particular embodiments, the tubular element further comprises a wrap.

In a specific embodiment, the porous medium loaded with gel completely fills the tubular element within the wrapper. Alternatively, in other specific embodiments, the porous medium only partially fills the tubular element.

In particular embodiments, the tubular element further comprises a second tubular element having longitudinal sides and proximal and distal ends, the second tubular element being positioned longitudinally within the first longitudinal channel formed by the wrap.

In a specific embodiment, the longitudinal side of the second tubular element comprises paper or cardboard or cellulose acetate.

In a specific embodiment, the second tubular element comprises a porous medium loaded with gel. However, in alternative embodiments, the second tubular element comprises a gel.

In some embodiments, the gel-loaded porous medium is positioned between the second tubular element and the wrap forming the first longitudinal channel in the presence of the first and second tubular elements and wrap as described above.

In some alternative embodiments, in the presence of the first tubular element and the second tubular element, a gel is positioned between the second tubular element and the wrap between the at least one longitudinal channel.

With additional features in particular embodiments, the tubular element includes a longitudinal element positioned longitudinally within the first longitudinal channel.

In combination with other features of particular embodiments, the wrap is rigid. Alternatively or additionally, in a specific embodiment, the longitudinal sides of the second tubular element are stiff.

In combination with other features of particular embodiments, the wrap is waterproof.

With additional features in certain embodiments, the tubular member further comprises a susceptor.

In particular embodiments, the gel-loaded porous media is pleated. The porous medium may be corrugated before or after loading with gel.

In a specific embodiment, the gel-loaded porous medium is shredded. The porous medium may be minced before or after loading with gel.

According to the present invention, there is provided a method of manufacturing a tubular element as claimed in any preceding claim,

the method comprises the following steps:

-dispensing the gel-loaded porous medium onto a web of wrapping material; the method comprises the steps of,

-dispensing a second tubular element onto said gel-loaded porous medium on said web of wrapping material;

-wrapping the web of wrapping material around the gel-loaded porous medium and the second tubular element to form a composite structure of gel-loaded porous medium and the second tubular element.

In a specific embodiment, the method of manufacturing a tubular element further comprises the steps of: the wrapped composite structure of the gel-loaded porous medium and the second tubular element is cut to length.

According to the present invention there is provided a tubular element comprising a wrapper forming a first longitudinal channel; the tubular element further comprises a gel; the gel comprises an active agent.

In particular embodiments, the gel completely fills the tubular element within the wrap.

Alternatively, in particular embodiments, the gel may partially fill the tubular element. For example, in a specific embodiment, the gel is provided as a coating on the inner surface of the tubular element. An advantage of only partially filling the tubular element is that it leaves a fluid path for e.g. aerosol to flow into or out of the tubular element.

In combination with specific embodiments, the tubular element comprises a second tubular element.

In combination with specific embodiments, the tubular element comprises a second tubular element comprising a longitudinal side and proximal and distal ends; and the second tubular member is longitudinally positioned within the first longitudinal channel.

In combination with specific embodiments, the tubular element comprises a plurality of second tubular elements.

In particular embodiments, the tubular element comprises a plurality of second tubular elements arranged in parallel so as to extend along the longitudinal length of the tubular element. Optionally, the gel is provided within all, some, or none of the plurality of second tubular elements. Again, depending on the particular embodiment, in the case where a gel is present in the second tubular element, the gel completely fills each of the plurality of second tubular elements, or the gel partially fills the second tubular elements.

In a specific embodiment, the tubular element comprises a porous medium loaded with gel.

In combination with other features, in particular embodiments one or more of the second tubular elements comprises a porous medium loaded with gel. In the presence of the gel-loaded porous medium, the gel-loaded porous medium completely fills each of the plurality of second tubular elements or the gel-loaded porous medium partially fills the second tubular elements.

In a specific embodiment, the gel-loaded porous medium is located between the second tubular element and the wrap.

In a specific embodiment, the second tubular element comprises a gel. Preferably, the gel is at least partially enclosed by the longitudinal sides of the second tubular element.

In particular embodiments, a gel may be located between the second tubular element and the wrap forming the first longitudinal channel.

In combination with specific embodiments, the outer diameter of the tubular element is approximately equal to the outer diameter of the aerosol-generating article.

In particular embodiments, the outer diameter of the tubular element is between 5 and 12 mm, for example between 5 and 10 mm, or between 6 and 8 mm. Typically, the outer diameter of the tubular element is 7.2 mm plus or minus 10%.

Typically, the length of the tubular element is between 5 mm and 15 mm. Preferably, the length of the tubular element is between 6 and 12 mm, preferably the length of the tubular element is between 7 and 10 mm, preferably the length of the tubular element is 8 mm.

In connection with a specific embodiment, the gel is a mixture of materials capable of releasing volatile compounds into an aerosol passing through the tubular element, preferably when the gel is heated. The provision of a gel may be advantageous to facilitate storage and transport, or during use, may be advantageous in that the risk of leakage from the tubular element, the aerosol-generating article or the aerosol-generating device may be reduced.

Advantageously, the gel is solid at room temperature. By "solid" in this context is meant that the gel has a stable size and shape and does not flow. Room temperature in this context means 25 degrees celsius.

The gel may include an aerosol former. Desirably, the aerosol former is substantially resistant to thermal degradation at the operating temperature of the tubular element. Suitable aerosol formers are well known in the art and include, but are not limited to: polyols such as triethylene glycol, 1, 3-butanediol, and glycerol; esters of polyols, such as glycerol mono-, di-, or triacetate; and fatty acid esters of mono-, di-or polycarboxylic acids, such as dimethyldodecanedioate and dimethyltetradecanedioate. The polyol or mixture thereof may be one or more of triethylene glycol, 1, 3-butanediol, and glycerol or polyethylene glycol.

Advantageously, for example, the gel comprises a thermoreversible gel. This means that the gel becomes fluid when heated to the melting temperature and becomes gel again at the gelling temperature. The gelation temperature may be at or above room temperature and atmospheric pressure. Atmospheric pressure means 1 atmosphere pressure. The melting temperature may be higher than the gelling temperature. The melting temperature of the gel may be greater than 50 degrees celsius, or 60 degrees celsius, or 70 degrees celsius, and may be greater than 80 degrees celsius. Melting temperature in this context means the temperature at which the gel is no longer solid and begins to flow.

Alternatively, in a specific embodiment, the gel is a non-molten gel that does not melt during use of the tubular element. In these embodiments, the gel may at least partially release the active agent in use at a temperature at or above the operating temperature of the tubular element but below the melting temperature of the gel.

Preferably, the viscosity of the gel is 50,000 to 10 pascals per second, preferably 10,000 to 1,000 pascals per second, to achieve the desired viscosity.

In combination with specific embodiments, the gel comprises a gelling agent. In specific embodiments, the gel comprises agar or agarose or sodium alginate or Gellan gum (Gellan gum), or mixtures thereof.

In particular embodiments, the gel comprises water, e.g., the gel is a hydrogel. Alternatively, in particular embodiments, the gel is non-aqueous.

Preferably, the gel comprises an active agent. In connection with particular embodiments, the active agent comprises nicotine (e.g., in powder form or liquid form) or a tobacco product or another compound of interest, e.g., for release in an aerosol. In a specific embodiment, nicotine is contained in the gel with an aerosol former. It is desirable to lock nicotine into the gel at room temperature to prevent leakage.

In particular embodiments, the gel comprises a solid tobacco material that releases flavor compounds when heated. Depending on the particular embodiment, the solid tobacco material is, for example, one or more of the following: a powder, granule, pellet, chip (shred), pasta, strip or sheet comprising one or more of the following: plant material such as grass leaf, tobacco rib, reconstituted tobacco, homogenized tobacco, extruded tobacco and expanded tobacco.

Alternatively or additionally, embodiments exist wherein, for example, the gel comprises other flavors, such as menthol. Menthol may be added to the water or to the aerosol former prior to the gel formation.

In embodiments where agar is used as the gelling agent, the gel comprises, for example, between 0.5 and 5 wt.% agar, preferably between 0.8 and 1 wt.%. Preferably, the gel further comprises between 0.1% and 2% by weight of nicotine. Preferably, the gel further comprises between 30 wt% and 90 wt% (or between 70 wt% and 90 wt%) glycerol. In particular embodiments, the remainder of the gel comprises water and a flavoring agent.

Preferably, the gelling agent is agar, which has the property of melting at a temperature above 85 degrees celsius and turning back to a gel at around 40 degrees celsius. This property applies to thermal environments. The gel does not melt at 50 degrees celsius, which is useful, for example, in the case where the system is left in a high temperature car in sunlight. The phase change to a liquid at around 85 degrees celsius means that the aerosol can be initiated by heating the gel to a relatively low temperature, thus achieving low energy consumption. It may be beneficial to use only agarose, which is one component of agar, instead of agar.

When gellan gum is used as the gelling agent, typically the gel comprises between 0.5 and 5 wt% gellan gum. Preferably, the gel further comprises between 0.1% and 2% by weight of nicotine. Preferably, the gel comprises between 30% and 99.4% by weight of glycerol. In particular embodiments, the remainder of the gel comprises water and a flavoring agent.

In one example, the gel comprises 2% by weight nicotine, 70% by weight glycerin, 27% by weight water, and 1% by weight agar.

In another example, the gel comprises 65 wt.% glycerin, 20 wt.% water, 14.3 wt.% tobacco, and 0.7 wt.% agar.

Additionally or alternatively, in some embodiments, the tubular element comprises a porous medium loaded with gel. Preferably, the gel-loaded porous medium is located between the second tubular element and a wrapper forming the first longitudinal channel. Alternatively, in some embodiments, the second tubular element comprises a porous medium loaded with gel. These embodiments do not necessarily exclude the gel, or additionally or alternatively, the gel-loaded porous medium is located elsewhere. In particular embodiments, the tubular element comprises a gel and a porous medium loaded with the gel.

In combination with specific embodiments, the tubular element comprises a longitudinal element positioned longitudinally within the first longitudinal channel. In a specific embodiment, the longitudinal element positioned longitudinally within the first longitudinal channel is a porous medium loaded with gel. In other embodiments, the longitudinal element may be a longitudinal element of any material capable of, for example, occupying space within the tubular element, or assisting in the transfer of heat or material, or even in the stiffness or rigidity of the structure.

In some embodiments, the wrap is hard or rigid to aid in the construction of the tubular element. It is envisioned that the gels used in the present invention are semi-solids capable of retaining shape, especially in use. However, the invention is not limited to solid gels. More fluid gels, gels having a higher viscosity than solid gels, may also be used with embodiments of the present invention. It is therefore advantageous to have a wrap that is itself capable of retaining the tubular element structure, however this is not necessary. Likewise, the longitudinal sides of the second tubular element may be rigid or stiff. Having a wrap or longitudinal side of the second tubular element, or both, which is stiff or substantially rigid, may facilitate the construction of the tubular element, but may also facilitate the manufacturing. Preferably, the wrap has a thickness of about 50 to 150 microns.

In combination with other features, in particular embodiments, the wrap is waterproof. In a specific embodiment, the longitudinal sides of the second tubular element are watertight. Such waterproofing properties of the wrap or longitudinal side of the second tubular element may be achieved by using a waterproofing material or by treating the material of the wrap or longitudinal side of the second tubular element. This may be achieved by treating one or both of the longitudinal sides or the wrap of the second tubular element. Having water resistance will help without losing structure, stiffness or rigidity. This may also help to prevent leakage of the gel or liquid, especially when using gels of fluid structures.

In combination with specific embodiments, the tubular element comprises a susceptor. The susceptor may be any heat transfer material, for example, it may be a wire of metal (e.g., aluminum wire) or wire containing aluminum or metal powder (such as, for example, aluminum powder). Typically, the susceptor is positioned longitudinally within the tubular element. The susceptor may be located in the gel, or adjacent to the gel, or in the vicinity of the gel; or in the gel-loaded porous medium or adjacent to the gel-loaded porous medium or in the vicinity of the gel-loaded porous medium.

In combination with specific embodiments, the tubular element further comprises a wire. This may be any material, natural or synthetic, but is preferably cotton. The threads may be carriers for active ingredients (e.g. flavors). One example of a suitable flavour for use in the present invention may be menthol. The wire may extend longitudinally within the tubular member. Preferably, the thread may be located within, adjacent to, or near the gel; or within or adjacent to the gel-loaded porous medium.

In combination with specific embodiments, the tubular element further comprises a sheet. In combination with specific embodiments, the gel-loaded porous medium comprises a sheet. By providing the gel-loaded porous medium as a sheet, there may be manufacturing advantages, for example, the sheets may be easily gathered together to form a suitable structure. The gel may be loaded into the sheet prior to being gathered together or after being gathered together.

According to the present invention there is provided a tubular element comprising a wrapper forming a first longitudinal channel, the tubular element further comprising a gel loaded porous medium further comprising an active agent.

In a specific embodiment, the second tubular element comprises a porous medium loaded with gel.

In some embodiments, in the presence of a first tubular element and a second tubular element as described, the gel-loaded porous medium is positioned between the second tubular element and the wrap forming the first longitudinal channel.

In some alternative embodiments, in the presence of a first tubular element and a second tubular element, a gel is positioned between the second tubular element and the wrap forming the first longitudinal channel.

the tubular element comprises:

at least one longitudinal channel and further comprising a gel; the gel comprises an active agent;

the method comprises the following steps:

-placing the material for the tubular element around a mandrel forming the tubular element;

-extruding the gel from a catheter within the mandrel such that the gel is within the tubular element.

The method may further comprise the steps of: the material for the tubular element is extruded around the mandrel to form the tubular element.

The manufacturing method may further include the steps of: wrapping the tubular element with a wrap.

the tubular element comprises:

a wrapper forming a first longitudinal channel and further comprising a porous medium loaded with gel; the gel-loaded porous medium further comprises an active agent; and wherein

The method comprises the following steps:

-dispensing the gel-loaded porous medium onto a web of wrapping material;

-wrapping the wrapping material around the gel-loaded porous medium.

In a specific embodiment, the method of manufacturing a tubular element further comprises the steps of: the wrapped tubular element is cut to length.

the tubular element comprises:

-forming a wrap of the first longitudinal channel and further comprising a porous medium loaded with gel; the gel-loaded porous medium further comprises an active agent; and

-a second tubular element.

The method comprises the following steps:

-wrapping the wrapping material around the gel-loaded porous medium and the second tubular element.

In particular embodiments, the method of manufacturing a tubular element further comprises cutting the wrapped tubular element to length.

The tubular element of the present invention is envisioned for use in aerosol-generating articles. It is also envisioned that the aerosol-generating article may be used in devices such as aerosol-generating devices. The aerosol-generating device may be used to hold and heat the aerosol-generating article to release material. In particular, this may be the release of material from the tubular element of the invention.

According to the present invention there is provided an aerosol-generating article for generating an aerosol, the aerosol-generating article comprising:

-a fluid guide allowing movement of a fluid; a fluid guide having a proximal end and a distal end, the fluid guide having an inner longitudinal region and an outer longitudinal region separated by a barrier; wherein the inner longitudinal region comprises an inner longitudinal channel between the distal end and the proximal end and the outer region comprises a longitudinal channel that communicates an external fluid to the distal end of the fluid guide through at least one aperture such that the external fluid may travel along the outer longitudinal channel to the distal end of the fluid guide;

-a tubular element comprising a gel; the gel comprises an active agent; the tubular member has a proximal end and a distal end and is distal to the fluid guide.

In particular embodiments, the barrier separating the inner longitudinal channel and the outer longitudinal channel may be an impermeable barrier, e.g. a fluid impermeable barrier.

According to the present invention there is provided an aerosol-generating article comprising:

-a fluid guide allowing movement of a fluid; the fluid guide having a proximal end and a distal end, the fluid guide having an inner longitudinal region and an outer longitudinal region separated by a barrier; wherein the inner longitudinal region comprises an inner longitudinal channel between the distal end and the proximal end; and the outer region includes an outer longitudinal channel that communicates an outer fluid to the distal end of the fluid guide through at least one aperture such that the outer fluid can travel along the outer longitudinal channel to the distal end of the fluid guide;

-a tubular element comprising a porous medium loaded with a gel, further comprising an active agent; the tubular member has a proximal end and a distal end and is distal to the fluid guide.

Preferably, in some embodiments, the distal end of the tubular element comprises at least one aperture. The aperture at the distal end of the tubular element may allow a fluid (e.g., air from outside the aerosol-generating article) to enter the tubular element and travel through the tubular element to generate an aerosol. The fluid traveling through the tubular element may pick up the active agent or any other material in the gel and transfer it from the gel through the downstream (proximal) direction.

In particular embodiments, the aerosol-generating article may comprise a lumen positioned between the distal end of the fluid guide and the proximal end of the tubular element. Thus, the lumen may be at an upstream end of the inner longitudinal channel and a downstream end of the tubular element. The lumen allows a fluid, such as ambient air, to travel through the outer longitudinal channel to the lumen and contact the gel in the tubular element. Fluid in contact with the tubular element may enter and pass through the tubular element before returning to the inner longitudinal channel and the proximal end of the fluid guide and the proximal end of the aerosol-generating article. When the fluid, e.g. ambient air, is in contact with the gel, the fluid may pick up the active agent or any other material in the gel or tubular element and transfer it along the downstream internal longitudinal channel to the proximal end of the aerosol-generating article. For contact with the gel, ambient air may pass through the tubular element or through the gel or through the surface of the gel, or a combination thereof.

In a specific embodiment, the at least one aperture is located in the outer channel of the fluid guide.

The at least one external communication hole having an external channel located in the fluid guide allows a distance between the tubular element and the at least one external communication hole. This can help prevent leakage of the gel and its contents, but also give the required aerosol traction.

In a specific embodiment, the at least one hole is located in a cavity between the fluid guide and the tubular element.

Having the at least one aperture in the outer channel of the fluid guide allows ambient fluid to easily reach the tubular element and to easily mix in the cavity between the tubular element and the fluid guide.

In a specific embodiment, the at least one aperture is located in a sidewall of the tubular element.

Having the at least one aperture in the sidewall of the tubular element allows the ambient fluid to travel substantially in one direction when negative pressure is applied to the proximal end of the aerosol-generating article. Having at least one aperture in the side wall of the tubular element allows ambient fluid to be easily mixed with the contents of the tubular element.

In a specific embodiment, the aerosol-generating article comprises a wrapper. For example, the wrapper may be any suitable material, for example, the wrapper may comprise paper. Preferably, the wrap will have a corresponding hole to the hole of the fluid guide. The corresponding apertures and wraps of the fluid guide may be created by apertures formed after wrapping the article.

In a specific embodiment, the outer longitudinal channel of the aerosol-generating article comprises a hole or holes. The aperture may be any aperture, slit, hole or channel that allows a fluid (e.g. ambient air) to pass through and into the aerosol-generating article. This allows fluid from outside the aerosol-generating article to be inhaled. In use, this may be an external fluid, such as air, which is first drawn into the aerosol-generating article through the aperture into the external longitudinal channel before being drawn into the other part of the aerosol-generating article. In particular embodiments, the apertures are evenly spaced around the circumference of the aerosol-generating article, e.g. there are 10 or 12 apertures. Having evenly spaced holes helps to give a smooth fluid flow.

In combination with a specific embodiment, the aerosol-generating article comprises an end plug located on the distal end of the tubular element, and wherein the end plug has a high resistance to suction. The end plug may be fluid impermeable or may be almost fluid impermeable. Preferably, the end plug is located at the very distal end of the aerosol-generating article. By means of the end plug having a high resistance to suction, this will advantageously bias the fluid into the hole through the outer longitudinal channel when a negative pressure is applied to the proximal end of the aerosol-generating article. In some embodiments, the end plug is fluid impermeable.

In some embodiments, the tubular element comprises an end plug. Advantageously, this allows for ease of manufacture. The end plug of the tubular element is preferably positioned at one end of the tubular element. Advantageously, this allows for ease of manufacture. In some embodiments, the tubular element comprises an end plug, wherein the end plug is fluid impermeable. When the tubular element comprises a fluid impermeable end plug, this prevents gels and other fluids from escaping from the tubular element through the end plug of the tubular element.

In particular embodiments, the internal longitudinal channel of the internal region of the fluid guide comprises a restrictor. In some embodiments, the restrictor is located at or near the proximal end of the fluid guide. In some embodiments, the restrictor is located at or near the downstream end of the fluid guide. However, if present, the restrictor may be positioned in the middle region of the inner longitudinal channel or in the middle region of the outer longitudinal channel of the fluid guide. The limiter may also be positioned at, near or at the distal end of the internal longitudinal channel. The restrictor may be positioned at or near the upstream end of the inner longitudinal channel. More than one restrictor may be used in the inner longitudinal channel or in the outer longitudinal channel of the fluid guide.

The limiter for some embodiments of the invention includes a sudden constriction; just as holes or gradual restrictions in the surface such as walls. Alternatively, in other embodiments, the restrictor comprises a gradual or smooth restriction, such as an inclined wall, or a funnel shape narrowing to the opening, or a gradual restriction across the width of the channel. There may be a gradual or abrupt widening at the downstream (proximal) side of the limiter. Particular embodiments include funnel shapes on one or both sides of the limiter. Thus, in the flow of fluid, there may be gradual flow restrictions from upstream to downstream (distal to proximal), such as a narrowing of the sides of the channel to the opening of the restrictor, followed by a gradual widening of the channel from the opening of the restrictor. Typically, the opening of the restrictor will have a restriction of 60% or 45% or 30% from the maximum cross-sectional area of the passageway. Thus in the present invention, in some embodiments, for example, the restrictor may comprise a constriction whose opening has a cross-sectional area of only 60% or 45% or 30% of the cross-sectional area of the largest or widest portion of the internal longitudinal passageway. Typically, embodiments of the present invention reduce the cross-sectional diameter of the cylindrical channel from, for example, 4 mm to 2.5 mm, or from 4 mm to 2.5 mm. By varying the different width reduction ratios and widths; positioning a limiter; a limiter number; as well as reduced gradients and widened gradients, specific fluid flow characteristics may be achieved.

In combination with a specific embodiment, the aerosol-generating article comprises a heating element like a susceptor, such that heat may be transferred into the gel in the tubular element. As with the susceptors of the tubular elements, this may be any suitable material, preferably for example aluminium or a metal comprising aluminium.

According to the present invention there is provided a method of manufacturing an aerosol-generating article comprising:

-a fluid guide allowing transfer of fluid; the fluid guide has a proximal end and a distal end, the fluid guide having an inner longitudinal region and an outer longitudinal region separated by a barrier; wherein the inner longitudinal region comprises an inner longitudinal channel between the distal end and the proximal end and the outer region comprises an outer longitudinal channel that conveys fluid to the distal end of the fluid guide through the at least one aperture such that fluid can travel along the outer longitudinal channel of the outer fluid control region to the distal end of the fluid guide;

-a tubular element comprising a gel; the gel comprises an active agent; a tubular member having a proximal end and a distal end; and, in addition, the processing unit,

the method comprises the following steps:

-arranging the tubular elements linearly, comprising the gel and the fluid guides on the web of wrapping material; and

-wrapping the tubular element and the fluid guide and positioning the wrap securely around the tubular element and the fluid guide.

According to the present invention there is provided an aerosol-generating device comprising a container configured to receive a distal end of an aerosol-generating article as described herein.

The container of the device may correspond in shape and size to allow a close fit of the distal end or a portion of the distal end of the aerosol-generating article and to retain the aerosol-generating article in the container during normal use.

Typically, the container includes a heating element. This will enable heating of the aerosol-generating article; heating the tubular element; or heating the gel, preferably comprising an active agent; or heating the gel-loaded porous medium; or any combination thereof; either directly or indirectly, assist in generating or releasing an aerosol, or release a material into an aerosol. The aerosol may then pass through the proximal end of the aerosol-generating article. In particular embodiments, heating is performed directly or indirectly by a thermal element or susceptor or a combination of both.

The heating means may be any heating means known. Typically, the heating means may be by radiation or conduction or convection, or a combination thereof.

In combination with specific embodiments, the tubular element further comprises a wire. In particular embodiments, the thread is a natural material or a synthetic material, or the thread is a combination of natural and synthetic materials. The thread may comprise a semi-synthetic material. The thread may be made of, or comprise, or partially comprise, fibres. The threads may be made of cotton, cellulose acetate or paper, for example. Composite wires may be used. The wire may help to make the tubular member containing the active agent. The wire may assist in introducing the active agent into the tubular element containing the active agent. The wire may help stabilize the structure of the tubular element containing the active agent.

In combination with specific embodiments, the tubular member comprises a porous medium loaded with a gel. Porous media may be used within the tubular member to create space within the tubular member. The porous medium is capable of retaining or holding a gel. This has the advantage of assisting in the transfer and storage of the gel and the manufacture of the tubular element comprising the gel. In porous media loaded with a gel, the gel may also contain an active agent; it may also contain or carry active agents or other materials.

The porous medium may be any suitable porous material capable of containing or holding a gel. Desirably, the porous medium may have the gel move within it. In particular embodiments, the gel-loaded porous medium comprises a natural material, a synthetic or semi-synthetic material, or a combination thereof. In particular embodiments, the gel-loaded porous medium comprises a sheet, foam, or fiber, such as loose fibers; or a combination thereof. In particular embodiments, the gel-loaded porous medium comprises a woven, nonwoven, or extruded material, or a combination thereof. Preferably, the porous media loaded with gel comprises, for example, cotton, paper, viscose, PLA or a combination of cellulose acetate. Preferably, the gel-loaded porous medium comprises a sheet material, such as cotton or cellulose acetate. An advantage of the porous media loaded with gel is that the gel remains within the porous media, which may facilitate manufacturing, storage or transportation of the gel. It may help to maintain the desired gel shape, particularly during manufacture, transport or use. The porous media used in the present invention may be pleated or chopped. In particular embodiments, the porous media comprises pleated porous media. In an alternative embodiment, the porous medium comprises a chopped porous medium. The wrinkling or shredding process may be before or after loading with gel.

Shredding allows the gel to be easily absorbed by the high surface area to volume ratio of medium.

In a specific embodiment, the sheet is a composite material. Preferably, the sheet is porous. The sheet material may assist in the manufacture of a tubular element comprising a gel. The sheet material may assist in introducing the active agent into the gel-containing tubular element. The sheet material may help to stabilize the structure of the tubular element comprising the gel. The sheet may assist in transporting or storing the gel. The use of a sheet may enable or facilitate the addition of structures to the porous medium, for example by corrugating the sheet. Wrinkling the sheet has the benefit of improving the structure to allow passage through the structure. The channels facilitate loading of the gel through the pleated sheet, hold the gel, and also facilitate passage of fluid through the pleated sheet. Thus, there are advantages to using pleated sheets as the porous media.

The porous medium may be a thread. The thread may comprise, for example, cotton, paper or acetate. The threads may also be loaded with gel, as any other porous medium. The advantage of using wire as the porous medium is that it aids in ease of manufacture. The wire may be preloaded with gel prior to use in manufacturing the tubular element, or the wire may be loaded with gel during assembly of the tubular element.

The threads may be loaded with gel by any known means. The wire may simply be coated with a gel, or the wire may be impregnated with a gel. In manufacture, the wire may be impregnated with a gel and stored ready for inclusion in the assembly of the tubular element. In other processes, the wire is subjected to a loading process in the manufacture of a tubular element loaded with gel. As with the gel-loaded porous media or gel alone, preferably the gel comprises an active agent. The active agent is as described herein.

In the manufacture of the tubular element, the gel or porous medium or thread may be dispensed simultaneously as the other components are dispensed or dispensed sequentially. Preferably, the components are dispensed, but may be gathered or rolled or combined or positioned in any known manner to locate them in the desired position.

As used herein, the term "active agent" is an agent capable of having activity, for example, that produces a chemical reaction or is capable of altering the aerosol produced. The active agent may be more than one agent.

As used herein, the term "aerosol-generating article" is used to describe an article capable of generating or releasing an aerosol.

As used herein, the term "aerosol-generating device" is a device for use with an aerosol-generating article to enable the generation or release of an aerosol.

As used herein, the term "aerosol former" refers to any suitable known compound or mixture of compounds that, in use, promotes the enhancement of an initial aerosol, for example, received into a tubular element, which may become a denser aerosol, a more stable aerosol, or a denser aerosol and a more stable aerosol.

As used herein, the term "aerosol-generating substance" is used to describe a substance capable of generating or releasing an aerosol.

As used herein, the term "aperture" is used to describe any aperture, slit, hole, or opening.

As used herein, the term "cavity" is used to describe any void or space at least partially enclosed in a structure. For example, in the present invention, the lumen is a partially enclosed space (in some embodiments) between the fluid guide and the tubular element.

As used herein, the term "chamber" is used to describe a space or cavity that is at least partially enclosed.

For the purposes of this disclosure, an internal longitudinal cross-sectional area that "collapses" from a first location to a second location is used to indicate a diameter decrease in the internal longitudinal cross-sectional area from the first location to the second location. These are commonly referred to as "limiters". Thus, as used herein, the term "restrictor" is used to describe a constriction in a fluid channel or a change in cross-sectional area in a fluid channel.

As used herein, the term "pleated" refers to a material having a plurality of ridges or corrugations. It also includes a process of wrinkling the material.

The expression "cross-sectional area" is used to describe the cross-sectional area measured in a plane transverse to the longitudinal direction.

For purposes of this disclosure, the term "diameter" or "width" as used herein is the largest transverse dimension of any of the tubular element, the aerosol-generating article or the aerosol-generating device, a portion thereof, the tubular element, the aerosol-generating article or the aerosol-generating device. For example, a "diameter" is the diameter of an object having a circular transverse portion, or the length of the diagonal width of an object having a rectangular cross section.

As used herein, the term "essential oil" is used to describe an oil that has a characteristic odor obtained and a flavor obtained from plants.

As used herein, the term "external fluid" is used to describe a fluid, such as ambient air, that originates from outside the aerosol-generating element, article or device.

As used herein, the term "perfume" is used to describe a composition that affects the sensory quality of an aerosol.

The term "fluid guide" is used herein to describe a device or component that can alter the flow of a fluid. Preferably, this is a fluid flow path that directs or directs the generated or released aerosol. The fluid guides may cause the fluids to mix. It may help accelerate the fluid as the channel narrows in cross-sectional area, it may help slow down the flow as the channel expands in cross-section moving along the channel.

As used herein, the term "gathered" is used to describe a sheet that is wrapped, folded or otherwise compressed or contracted generally transverse to the longitudinal axis of the aerosol-generating article or tubular element.

As used herein, the term "gel" is used to describe a solid jelly-like semi-rigid material that has the ability to hold other materials and release the materials into an aerosol.

The term "herbal material" is used to indicate material from herbs. "herbs" are aromatic plants in which the leaves or other parts of the plant are used for medicinal, culinary or aromatic purposes and are capable of releasing a taste into an aerosol produced by an aerosol-generating article.

The term "hydrophobic" as used herein refers to surfaces that exhibit water repellent properties. The hydrophobic properties can be expressed by water contact angle. The "water contact angle" is the angle through a liquid as conventionally measured when the liquid interface encounters a solid surface. It quantifies the wettability of a solid surface by a liquid via the young's equation.

As used herein, the term "impermeable" is used to describe an article, such as a barrier, that does not substantially or easily pass through.

As used herein, the term "induction heating" is used to describe heating an object by electromagnetic induction, wherein eddy currents (also known as Foucault currents) are generated within the object to be heated, and electrical resistance results in resistive heating of the object.

As used herein, the term "longitudinal channel" is used to describe a channel or opening along which a liquid or the like flows. Typically, air or generated aerosols carry material, such as solid particles, along the longitudinal channels. Typically, the longitudinal channels will be longer in longitudinal length and then wider but not necessarily. The term "longitudinal channel" also includes a plurality of more than one longitudinal channel.

The term "longitudinal" is used to describe the direction between the proximal and distal ends of a tubular element, an aerosol-generating article or an aerosol-generating device.

As used herein, "longitudinal side", e.g., the second tubular element, is used to describe the longitudinal side or wall of the second tubular element. In some embodiments, this is, for example, a unitary body of cellulose acetate or gel-loaded porous media forming a tubular element. In an alternative embodiment, the longitudinal sides are wrappers.

As used herein, the term "mandrel" is used to describe a shaft that is forged or formed from another material.

As used herein, the term "mint" is used to refer to a mint-like plant.

The term "mouthpiece" is used herein to describe an element, component or portion of an aerosol-generating article through which an aerosol exits the aerosol-generating article.

As used herein, the term "outer" is used with reference to the fluid guide to describe a portion of the longitudinal periphery of the fluid guide that is more toward the fluid guide than the middle of the cross-sectional portion of the fluid guide. Similarly, the term "interior" is used to describe (refer to a fluid guide) that portion of the fluid guide that is the center of the cross-sectional portion, rather than near the periphery of the fluid guide.

As used herein, the term "channel" is used to describe a channel between which access may be allowed.

As used herein, the term "plasticizer" is used to describe a substance, typically a solvent, that adds or promotes plasticity or flexibility, and reduces brittleness.

The term "porous medium" as used herein is used to describe any medium capable of holding, retaining or supporting a gel. Typically, the porous medium will have channels within its structure that can be filled to hold or retain a fluid or semi-solid, such as a gel. Preferably, the gel is also capable of transfer or transfer along channels within the porous medium. As used herein, the term "gel-loaded porous medium" is used to describe a porous medium comprising a gel. The gel-loaded porous medium is capable of holding, retaining or supporting a quantity of gel.

As used herein, the term "plug" is used to describe a component, section or element for an aerosol-generating article. As used herein, the term "end plug" is used to describe the most distal part at the distal end of an aerosol-generating article or a plug of an aerosol-generating article. Preferably, the end plug will have a high resistance to suction (RTD).

The term "proton donating" refers to a group capable of providing hydrogen or protons in a chemical reaction.

By the term "container" of the aerosol-generating device, the term is used to describe a chamber of the aerosol-generating device capable of receiving a portion of an aerosol-generating article. This is typically, but not necessarily, the distal end of the article.

As used herein, the term "resistance to suction" (RTD) is used to describe the resistance of a fluid, such as a gas, to suction through a material. As used herein, aspiration resistance is expressed in units of pressure "mm WG" or "water meter millimeters" and is measured according to ISO 6565:2002.

As used herein, the term "high resistance to aspiration" (RTD) is used to describe the resistance of a fluid, such as a gas, to aspiration through a material. As used herein, high suction resistance means greater than 200"mm WG" or "water meter millimeters" and measured according to ISO 6565:2002.

As used herein, the term "sheet" is used to describe a generally planar layered element having a width and length substantially greater than its thickness.

As used herein, the term "seal" is a joint or "joint" made, for example, by joining edges of the wrap to each other or to the fluid guide. This may be through the use of adhesives or glues. However, the term seal also includes interference fit connections. The seal does not require the manufacture of a liquid impermeable seal or barrier.

As used herein, the term "shredding" is used to describe fine cut things.

As used herein, the term "rigid" is used to describe an article that is sufficiently rigid, or sufficiently rigid to resist shape change, or sufficiently resistant to deforming shapes under normal use. This includes that it may be resilient so that if deformed it can return to its original shape to a large extent. Likewise, the term "rigid" as used herein describes that the article is resistant to bending or forced out of shape, generally capable of retaining its shape, especially under normal use.

As used herein, the term "susceptor" is used to describe a heating element, any material capable of absorbing electromagnetic energy and converting it into heat. For example, in the present invention, a susceptor or thermal element may assist in transferring thermal energy into the gel, heating the gel to assist in releasing material from the gel.

As used herein, the term "textured sheet" refers to a sheet that has been curled, embossed, gravure, perforated, or otherwise deformed.

As used herein, the term "gel loaded strand" is used to describe a strand of porous media that holds, retains or supports a gel, including, for example, coating or impregnating with a gel.

In this document, the term "tubular element" is used to describe a component suitable for use in an aerosol-generating article. Desirably, the longitudinal length of the tubular element may be longer than the width, but is not required as it may be part of a multicomponent article whose longitudinal length is desirably longer than its width. Typically, the tubular element is cylindrical, but not necessarily. For example, the tubular element may have an elliptical, triangular-like or rectangular polygonal or irregular cross-section. The tubular element need not be hollow.

The terms "upstream" and "downstream" are used to describe the relative position with respect to the direction of the mainstream fluid as it is drawn into the tubular element, aerosol-generating article or aerosol-generating device. In some embodiments, where fluid enters from the distal end of the aerosol-generating article and travels toward the proximal end of the article, the distal end of the aerosol-generating article may also be described as the upstream end of the aerosol-generating article and the proximal end of the aerosol-generating article may also be described as the downstream end of the aerosol-generating article. In these embodiments, the element of the aerosol-generating article located between the proximal and distal ends may be described as being upstream of the proximal end, or alternatively downstream of the distal end. However, in other embodiments of the invention, wherein the fluid enters the aerosol-generating article from the side and travels first towards the distal end of the aerosol-generating article, turns and then travels towards the proximal end of the aerosol-generating article, the distal end of the aerosol-generating article may be upstream or downstream, depending on the respective reference point.

As used herein, the term "waterproof" is used to describe a material of the second tubular element, such as a wrap or longitudinal side, which does not allow water to easily pass through or be damaged by water. The waterproof material is resistant to water penetration.

In particular embodiments, the tubular element comprises an active agent. In particular embodiments, the gel comprises an active agent. In a specific embodiment, the active agent comprises nicotine. In particular embodiments, the gel or tubular element comprising the active agent comprises 0.2 to 5 wt% active agent, for example 1 to 2 wt% active agent.

Generally, in particular embodiments, the tubular element will comprise at least 150mg of gel.

In particular embodiments, the active agent comprises a plasticizer.

In particular embodiments, the gel comprising the active agent comprises an aerosol former, such as glycerol. In an embodiment of the active agent containing aerosol precursor, the active agent containing gel comprises 60 to 95 wt% glycerol, for example 80 to 90 wt% glycerol.

In particular embodiments, the gel comprising the active agent comprises a gelling agent, such as an alginate, gellan, guar, or combination thereof. In embodiments comprising a gellant, the gel typically comprises from 0.5 wt% to 10 wt% of the gellant, e.g., from 1 wt% to 3 wt% of the gellant.

In particular embodiments, the gel comprises water. In such embodiments, the gel generally comprises 5 to 25 wt% water, for example 10 to 15 wt% water.

Preferably, the gel comprises a gelling agent. The gelling agent may form a solid medium in which the aerosol former may be dispersed.

The gel may include any suitable gelling agent. For example, the gelling agent may comprise one or more biopolymers, for example two or three biopolymers. Preferably, where the gel comprises more than one biopolymer, the biopolymers are present in substantially equal weight. The biopolymer may be formed from a polysaccharide. Biopolymers suitable for use as the gelling agent include, for example, gellan gum (natural low acyl gellan gum, high acyl gellan gum, preferably low acyl gellan gum), xanthan gum, alginate (alginic acid), agar, guar gum, and the like. Preferably, the gel comprises agar.

The gel may include any suitable amount of gelling agent. For example, the gel comprises a gelling agent in the range of about 0.5 wt% to about 7 wt% of the gel. Preferably, the gel comprises a gelling agent in the range of about 1 wt% to about 5 wt%, such as about 1.5 wt% to about 2.5 wt%.

In some preferred embodiments, the gel comprises agar in the range of about 0.5 wt% to about 7 wt%, or in the range of about 1 wt% to about 5 wt%, or about 2 wt%.

In some preferred embodiments, the gel comprises xanthan gum in the range of about 2 wt% to about 5 wt%, or in the range of about 2 wt% to about 4 wt%, or about 3 wt%.

In some preferred embodiments, the gel comprises xanthan gum, gellan gum, and agar. The gel may include xanthan gum, low acyl gellan gum and agar. The gel may comprise substantially equal weights of xanthan gum, gellan gum, and agar. The gel may comprise substantially equal weight of xanthan gum, low acyl gellan gum, and agar. The gel may comprise xanthan gum, low acyl gellan gum, and agar in the range of about 1 wt.% to about 5 wt.% (for the total weight of the xanthan gum, low acyl gellan gum, and agar), or in the range of about 1 wt.% to about 4 wt.% or about 2 wt.%. The gel may include xanthan gum, low acyl gellan gum, and agar in the range of about 1% to about 5% by weight, or about 2% by weight, wherein the weights of xanthan gum, gellan gum, and agar are substantially equal.

The gel may include divalent cations. Preferably, the divalent cations include calcium ions, such as calcium lactate in solution. Divalent cations (e.g., calcium ions) can aid in gel formation of compositions comprising biopolymers (polysaccharides) such as gellan gum (natural, low acyl gellan gum, high acyl gellan gum), xanthan gum, alginate (alginic acid), agar, guar gum, and the like. Ionic effects can aid gel formation. The divalent cation may be present in the gel composition in the range of about 0.1 wt% to about 1 wt% or about 0.5 wt%. In some embodiments, the gel does not include divalent cations.

The acid may comprise a carboxylic acid. The carboxylic acid may comprise a ketone group. Preferably, the carboxylic acid comprises a ketone group having less than 10 carbon atoms. Preferably, the carboxylic acid has five carbon atoms (e.g., viologen acid). Levulinic acid can be added to the neutralized pH of the gel. This may also aid in gel formation of compositions comprising biopolymers (polysaccharides) such as gellan gum (low acyl gellan gum, high acyl gellan gum), xanthan gum, especially alginate (alginic acid), agar, guar gum, and the like. Levulinic acid can also enhance the sensory profile of the gel formulation. In some embodiments, the gel does not include a carboxylic acid.

In particular embodiments, the active agent comprises a flavor or a pharmaceutical substance, or a combination thereof. In a specific example, the active agent is nicotine in any form. The active agent can be active, for example, capable of producing a chemical reaction or at least altering the aerosol produced.

The active agent may be a flavor. In particular embodiments, the active agent comprises a perfume. The gel may include a fragrance. Alternatively or in addition, the fragrance may be present at one or more other locations of the article. The fragrance may impart a flavor to aid in the taste of the fluid or aerosol produced by the article. A fragrance is any natural or artificial compound that affects the organoleptic quality of an aerosol. Plants useful for providing fragrances include, but are not limited to, those belonging to the following families: labiatae (Lamiaceae) (e.g., peppermint), umbelliferae (Apiaceae) (e.g., pimpinella, fennel), lauraceae (Lauraceae) (e.g., laurel, cinnamon, rosewood), rutaceae (Rutaceae) (e.g., citrus fruit), myrtaceae (Myrtaceae) (e.g., fennel myrtle), and Fabaceae (Fabaceae) (e.g., licorice). Non-limiting examples of flavor sources include mints such as peppermint and spearmint, coffee, tea, cinnamon, clove, ginger, cocoa, vanilla, eucalyptus, geranium, agave, and juniper; and combinations thereof.

Many fragrances are essential oils, or mixtures of one or more essential oils. Suitable essential oils include, but are not limited to, eugenol, peppermint oil, and spearmint oil. In many embodiments, the perfume comprises menthol, butenol, or a combination of menthol and eugenol. In many embodiments, the perfume further comprises a benzene alcohol, an alkene-addition-removal solution, or a combination thereof. In particular embodiments, the perfume comprises herbal material. Herbal materials include herbal leaves or other herbal materials from herbs including, but not limited to, peppermint (e.g., peppermint and spearmint), melissa leaf, perilla, cinnamon, lemon perilla, chive (chive), caraway, lavender, sage, tea, thyme, and caraway. Suitable types of mint leaves may be selected from plant varieties including, but not limited to, peppermint (Mentha piperita), field mint (Mentha arvensis), egyptian mint (Mentha nilica), lemon mint (Mentha citata), spearmint (Mentha spicata), spearmint (Mentha spicata crispa), spearmint (Mentha cordifolia), peppermint (Mentha longifolia), mentha pulegium, apple mint (Mentha suaveolens), and flower She Yuanshe mint (Mentha suaveolens variegata). In some embodiments, the flavor may comprise tobacco material.

In one specific example, in combination with other features, the gel comprises about 2% by weight nicotine, 70% by weight glycerin, 27% by weight water, and 1% by weight agar. In another embodiment, the gel comprises 65% by weight glycerol, 20% by weight water, 14.3% by weight solid powdered tobacco and 0.7% by weight agar.

In the present invention, the fluid guide may have two different regions, for example an outer region having an outer longitudinal channel and an inner region having an inner longitudinal channel. Thus, the outer longitudinal channel is longitudinally adjacent to the periphery of the fluid guide, and the inner fluid channel extends longitudinally along the cross-section of the longitudinal axis to the cross-section of the core.

Preferably, in a particular embodiment, ambient air passes through the aperture, enters the outer longitudinal channel of the distal end of the aerosol-generating article (the fluid guide) in the wrapper and aperture in the fluid guide, and the gel comprises an active agent in the region comprising the tubular element. Preferably, the fluid will be contacted with the gel containing the active agent to produce or release an aerosol comprising a mixture of fluids from outside the aerosol, as well as materials released from the gel containing the active agent or agent. The fluid then travels along the inner longitudinal channel of the fluid guide towards the proximal end of the aerosol-generating article. It is contemplated that the outer and inner longitudinal channels are separated by a barrier. The barrier may be impermeable to fluid or resistant to fluid passing through it, and thus be able to bias fluid distally. Preferably, the outer longitudinal channel of the fluid guide comprises an aperture in fluid communication with the outer portion of the fluid guide, and the outer portion of the article. It is also envisioned that the outer longitudinal channel is blocked at its proximal end such that, in use, fluid received from outside the aerosol-generating article flows primarily towards the distal end of the fluid guide. The outer longitudinal channel of the fluid guide has a hole at or near its proximal end, but is only open at its distal end. Instead, the inner longitudinal channel of the fluid guide is open at its proximal end and its distal end, although it may have various flow restricting elements between its proximal and distal ends. The barrier separating the inner and outer longitudinal channels of the fluid guide forces the fluid forcing the fluid entering the outer longitudinal channel into the distal end of the outer longitudinal channel and towards the tubular element, preferably comprising a gel comprising an active agent. This allows fluid in contact with the tubular element, which preferably comprises a gel comprising the active agent.

The outer longitudinal channel of the fluid guide may be one channel or more than one channel. The outer longitudinal channel may be within the fluid guide or may be one or more channels on the outer surface of the fluid guide, the fluid guide forming part of the wall of the outer longitudinal channel and the wrap forming another part of the wall to the outer longitudinal channel. The outer or inner longitudinal channel of the fluid guide may comprise a porous material, such as foam, in particular reticulated foam, such that the channel passes through the porous material. In particular embodiments, the fluid guide comprises a porous material, such as a foam. The porous material may allow fluid to pass through while maintaining its shape. These materials are easy to shape and thus may assist in the manufacture of aerosol-generating articles.

In some embodiments, the outer longitudinal channel may extend substantially around the interior of the wrapper. In some embodiments, the channel may extend less than the interior of the wrap.

Various aspects or embodiments of aerosol-generating articles for use with the aerosol-generating devices described herein may provide one or more advantages over currently available or previously described aerosol-generating articles. For example, an aerosol-generating article comprising a fluid guide, comprising a fluid guide and an internal fluid channel, allows for efficient transfer of aerosol generated from a gel-containing tubular element, preferably containing an active agent. Furthermore, gels containing active agents are less likely to leak out, forming aerosol-generating articles rather than liquid elements containing active agents.

The aerosol-generating article may comprise a mouth end (proximal end); and a distal end. Preferably, the distal end is received by an aerosol-generating device having a heating element for heating the distal end of the aerosol-generating article. A tubular element comprising a gel, preferably comprising an active agent, is preferably arranged near the distal end of the aerosol-generating article. Thus, the aerosol-generating device may heat the tubular element comprising the gel, preferably the active agent contained in the aerosol, to generate the article to produce an aerosol comprising the active agent.

The aerosol-generating article or portion of an aerosol-generating article comprising the tubular element, preferably comprising the active agent-containing gel, may be a disposable aerosol-generating article or a multi-use aerosol-generating article. In some specific embodiments, portions of the aerosol-generating article may be reused and the portions are disposable after a single use. For example, the aerosol-generating article may comprise a reusable mouthpiece, and a single-use portion comprising a tubular element comprising a gel and an active agent, e.g. further comprising nicotine. In embodiments that include both a reusable portion and a disposable portion, the reusable portion may be removed from the disposable portion.

In combination with specific embodiments, the aerosol-generating article comprises a wrapper. The aerosol-generating article may have an open end, a proximal end, and a distal end, which may be open or closed in different embodiments. Preferably, a tubular element is provided, preferably near the distal end of the aerosol-generating article, the tubular element preferably comprising an active agent-containing gel, the gel optionally comprising nicotine. Applying negative pressure on the open proximal end may release material in the tubular member, preferably comprising a gel containing the active agent. The aerosol-generating article defines at least one aperture between the proximal end and the distal end. The at least one aperture defines at least one fluid inlet such that upon application of negative pressure to the open proximal end of the aerosol-generating article, fluid, such as air, enters the aerosol-generating article through the aperture. Preferably, a fluid, such as ambient air, is drawn into the aerosol-generating article through the aperture, along the outer longitudinal channel of the fluid guide, towards the tubular element near the distal end of the aerosol-generating article, the tubular element preferably comprising a gel (the gel comprising an active agent). The fluid then flows from the distal end to the proximal end through the internal longitudinal channel of the fluid guide and out of the aerosol-generating article at the open proximal end.

By spacing the aperture from the distal end of the aerosol-generating article, the aperture is separated from the tubular element containing the gel, thereby reducing the likelihood of leakage of the gel through the aperture. Furthermore, by providing an airflow passage from the aperture to the tubular element containing the gel, such as an external longitudinal passage, fluid from the aperture may be directed towards the gel, and the fluid guide may act as another barrier between the gel and the aperture. This has the advantage of further reducing the likelihood of leakage of the tubular element through the bore. In addition, the inner longitudinal channel of the fluid guide provides a path for withdrawing, for example, air and fluids and materials generated or released from the tubular element from the aerosol-generating article through the open proximal end. The path provided by the inner longitudinal channel of the fluid guide may have an inner longitudinal flow cross-sectional area that varies along the length of the inner longitudinal channel to vary the flow of aerosol generated or released from the tubular element from the distal end of the aerosol-generating article to the open proximal end of the aerosol-generating article.

In combination with specific embodiments, the aerosol-generating article comprises a fluid guide. The aerosol-generating article and the fluid guide or parts thereof may be formed as a single part or as separate components. An advantage of the fluid-directing and aerosol-generating article is that it is integrally formed as a single part, it is only one part that is manufactured instead of a plurality of parts, which are then subsequently assembled within the aerosol-generating article. However, if the aerosol-generating article is a multi-component structure requiring multiple components, this has the advantage that different components can be changed more easily without changing the overall manufacturing process. Also, for the same reason, the fluid director may be formed as a single piece or as separate pieces—if integrally manufactured as one piece, it is easy to manufacture, but can be more easily accommodated if the components of the fluid director are assembled. The fluid guide is disposed in the aerosol-generating article and has a proximal end, a distal end, and an internal longitudinal passageway therebetween.

The inner longitudinal channel of the fluid guide has an inner cross-sectional area.

Providing an opening or channel that is angled with respect to the longitudinal direction of the aerosol-generating article has the advantage that during use fluid is directed into the proximal cavity at an angle to the flow of the mainstream fluid. This advantageously optimizes the mixing of the fluids and creates a resistance to suction (RTD). Mixing may also increase turbulence in the flow of the generated aerosol and air through or near-end lumen. These effects on the flow dynamics of the main flow create aerosols that may enhance the benefits described above. The desired resistance to suction can be achieved by varying the opening or channel dynamics, for example by making the channel smaller or larger in cross-sectional area, or by varying the angle of the walls of the channel, or a combination thereof. Such channels, in particular when the channel is contracted, are referred to as restrictors or flow restriction elements. Either the outer and inner longitudinal channels may have a limiter according to the invention, but preferably only the inner longitudinal channel comprises a limiter. To assist in describing the various embodiments described below, only the fluid flow and direction of the channels are described, and only the internal longitudinal channels are described. However, restrictors may also be used with the outer longitudinal channels of the present invention, wherein the fluid flow is generally in the opposite direction to the inner longitudinal fluid flow path. The general flow path in the outer longitudinal channel is proximal to distal, while in the inner longitudinal channel the general flow direction in use is distal to proximal. The ventilation fluid passing through the aperture enters the aerosol-generating article and flows distally along the external longitudinal channel. The fluid is contacted with a tubular element, preferably comprising a gel, which contains the active agent, and preferably generates or releases an aerosol containing the active agent, or other contents of the tubular element.

Limiters have been provided in smoking articles and aerosol-generating articles to compensate for low RTD (resistance to draw). For example, the restrictor may be embedded in a plug or tube of filter material. Furthermore, the filter segments comprising the restrictor may be combined with other filter segments, which may optionally comprise other additives, such as adsorbents or fragrances.

Preferably, in the cross-sectional area of the restrictor, each channel extends along a radius of the cross-sectional area or along a line of deviation of the angle β (β) from the radius. "radius" refers to any line extending from the center of the cross-sectional area to the edge of the cross-sectional area. The angle beta (beta) is measured as the minimum angle between the radius of the channel and the central axis. In the case of a non-straight channel, the angle may be measured between the longitudinal axis of the filter and the outlet of the channel.

The angle β (β) may be directed in a clockwise or counter-clockwise direction relative to the radius when viewing the cross-sectional area (distal end to distal end of the inner longitudinal channel) from the downstream direction.

In the case of a channel offset from the radius, the angle β (β) is preferably less than 60 degrees, more preferably less than 45 degrees, and even more preferably less than 15 degrees in the clockwise or counterclockwise direction. In the event that the angle beta (beta) deviates from the radius, the mixing of any fluid produced by the article and the ventilation fluid may be enhanced. In some cases, all channels may be directed in a clockwise direction or a counter-clockwise direction, or some channels may be directed in a clockwise direction, and some of them directed in a counter-clockwise direction.

The size of the openings or channels of the fluid guide preferably provides 1.0 square millimeters and 4.0 square millimeters (mm) ² ) More preferably 1.5 square millimeters and 3.5 square millimeters (mm) ² ). Preferably, the opening or channel of the inner longitudinal channel of the fluid guide is substantially circular, although other shapes of cross-section are possible. An advantage of the inner longitudinal channel of the fluid guide is that it is circular in cross-section, allowing a more uniform fluid flow over channels of non-circular cross-section. Changing the shape of the channels allows the desired flow to be achieved.

A single opening or channel may be provided in the fluid guide. Alternatively, two or more spaced openings or channels may be provided in the fluid guide. For example, in one embodiment, a pair of substantially opposed channels are provided. It is advantageous to have more than one channel to allow increased control of fluid flow through the channels. Having a channel is advantageous for ease of manufacture.

With respect to the inner and outer longitudinal channels where there are two or more openings or channels, the openings or channels may have the same open area as each other or different open areas. It is advantageous for two or more channels to have the same open area, all of which are advantageous so that fluid can even flow through all channels. However, two or more channels with different open areas are advantageous to create turbulence of the fluid as it passes through the two or more channels.

Two or more channels may be provided at the same or different angles to the longitudinal axis. It is advantageous to have two or more channels at the same angle as the longitudinal axis, so that fluid can even flow through all channels. In general, even fluid flows are easier to predict and design. Having two or more channels at an angle different from the longitudinal axis is advantageous because it creates turbulence of the fluid by passing through the two or more channels. Generally, turbulent airflow may improve agglomeration of particles to form aerosol droplets.

Two or more channels may be provided at the same or different angles to the radius of the transverse cross-section of the fluid guide. It is advantageous if two or more channels with a radius from the transverse cross-section of the fluid guiding region allow fluid to flow through all channels. Having two or more channels at different angles in the radius of the transverse cross-section of the fluid guide is advantageous in creating turbulence of the fluid because it passes through the two or more channels.

With respect to the inner and outer longitudinal channels, where there are two or more channels, the channels may be positioned at substantially the same location along the length of the fluid guide or at different longitudinal positions from each other. It is advantageous to have two or more channels at the same location along the length of the fluid guide, allowing fluid to flow through all channels. Having two or more channels with each other at different longitudinal positions is advantageous because it creates turbulence of the fluid as it passes through the two or more channels.

In an embodiment, an aperture is provided upstream of the cavity, an external longitudinal channel between the aperture and the cavity allowing fluid to flow from outside the aerosol-generating article, distally at the cavity and beyond the tubular element of the cavity. Direction. The cavity may be partly enclosed by the wrapper of the aerosol-generating article. In such embodiments, mixing of the fluid, e.g., ambient air, with the generated or released aerosol may occur or partially occur before the aerosol passes through the limiter.

Where the fluid guide comprises two or more restrictors of different size cross-sectional areas, preferably the first upstream restrictor has the smallest cross-sectional area. Preferably, the first restrictor has a reduced outer diameter compared to the total diameter of the internal longitudinal channel so as to form an annular channel between the distal and proximal sides.

In a particular embodiment, the limiter is substantially spherical. However, alternative shapes are also possible. The restrictor element may for example be substantially cylindrical or provided as a membrane. For example, the limiter may act as a membrane extending in a plane perpendicular to the longitudinal axis of the article.

In an alternative design, the limiter may be a polymer of small particles (e.g., microparticles immobilized by an adhesive).

In connection with particular embodiments, the cross-sectional area of the internal longitudinal channel of the fluid guide is substantially constant from the distal end to the distal end of the proximal end. This enables smooth fluid flow. The inner diameter of the inner longitudinal channel of the fluid guide is typically in the range of 1 to 5 mm, typically about 2 mm. The internal longitudinal channel generally has an internal longitudinal cross-sectional area that is less than the cross-sectional area of the lumen at the distal end of the fluid guide. In this way, the fluid guide has a limited internal longitudinal cross-sectional area for accelerating air entering the distal internal longitudinal channel.

In connection with particular embodiments, the cross-sectional area of the interior longitudinal passageway varies from the distal end to the proximal end. This force forces the fluids to mix. For example, the cross-sectional area at the distal end of the inner longitudinal channel may be greater than the cross-sectional area at the proximal end of the inner longitudinal channel. Where the cross-sectional area of the internal longitudinal passageway is greater at the distal end than at the distal end of the proximal end, the diameter of the internal longitudinal passageway of the proximal end is preferably between 0.5 mm and 3 mm, such as about 1 mm, and the diameter of the internal longitudinal passageway of the distal end is preferably between 1 mm and 5 mm, such as about 2 mm.

In connection with the specific embodiment, the fluid guide is preferably 3 mm to 50 mm and the length is preferably about 25 mm.

In combination with a specific embodiment, the internal longitudinal channel of the fluid guide may have one or more portions disposed between the distal and proximal ends adapted to vary the flow of fluid through the internal longitudinal channel from the distal end to the proximal end.

The inner longitudinal channel of the fluid guide may include a first portion between the proximal end and the distal end configured to accelerate fluid as it flows from the distal end toward the proximal end of the fluid guide. The first portion of the inner longitudinal channel may be configured in any suitable manner to accelerate the fluid as it flows through the inner longitudinal channel from the inboard end toward the proximal end of the inner longitudinal channel. For example, the first portion of the internal longitudinal channel may include a restrictor defining a restricted internal longitudinal cross-sectional area that forces the fluid to accelerate substantially axially from the distal end toward the proximal end. Preferably, the first portion of the internal longitudinal channel is a first portion of the internal longitudinal channel in a distal-to-proximal direction.

In combination with the specific embodiment, the internal longitudinal cross-sectional area of the first portion of the internal longitudinal channel may constrict from a position closer to the distal end of the fluid director to a position closer to the proximal end of the fluid director as it flows proximally from the distal end, the fluid accelerating. The interior longitudinal cross-sectional area of the first portion may be constrained from the distal end of the first portion to the proximal end of the first portion. Thus, the inner diameter of the distal end of the first portion of the inner longitudinal channel (closer to the distal end of the fluid guide) may have a larger inner diameter than the proximal end of the first portion (the position of the fluid guide closer to the proximal end).

In combination with certain embodiments, the inner longitudinal cross-sectional area of the first portion of the inner longitudinal channel may be constant from the distal end of the first portion to the proximal end of the first portion. In such embodiments, the constant internal longitudinal cross-sectional area of the first portion of the internal longitudinal channel may be less than the internal longitudinal cross-sectional area at the distal end of the internal longitudinal channel.

Where the internal longitudinal channel of the fluid guide tapers from the distal end to the proximal end, the taper of the internal longitudinal channel generally includes a gradual decrease in the cross-sectional area of the internal longitudinal channel from the distal end to the proximal end of the fluid guide. Preferably, the reduction in diameter of the inner longitudinal channel is linear from the distal end to the proximal end of the first portion, such as frustoconical. A linear reduction in cross-sectional area, such as a frustoconical shape, is advantageous for creating a smooth flow of fluid through the fluid guide.

Alternatively, the shrinkage is non-uniform. For example, in particular embodiments, the constriction of the inner longitudinal passageway is stepped, with the cross-sectional area of the inner longitudinal passageway being in discrete increments or steps from the distal end to the proximal end. The non-uniform reduction in cross-sectional area of the internal longitudinal channel is advantageous in creating turbulence in the fluid as it passes along the fluid guide.

The inner longitudinal channel of the fluid guide may include a second portion between the proximal end and the distal end configured to decelerate the fluid as it flows from the distal end toward the proximal end of the fluid guide. The second portion of the internal longitudinal passageway may be configured in any suitable manner to decelerate the fluid as it flows through the internal longitudinal passageway from the distal end toward the proximal end of the internal longitudinal passageway. For example, the first portion of the internal longitudinal channel may include a guide defining an expanded internal longitudinal cross-sectional area that forces the fluid to decelerate in a substantially axial direction from the distal end to the proximal end. Preferably, the second portion of the internal longitudinal channel is subsequent to the first portion in the distal-to-proximal direction.

In combination with certain embodiments, the internal longitudinal cross-sectional area of the first portion of the internal longitudinal channel may expand from a position closer to the distal end of the fluid director to a position closer to the proximal end of the fluid director as it flows from the distal end to the proximal end, the fluid decelerating. The internal longitudinal cross-sectional area of the first portion may extend from the distal end of the second portion to the proximal end of the second portion of the fluid director. Thus, the inner diameter of the distal end of the second portion of the inner longitudinal channel (the location proximal to the distal end of the fluid guide) may be smaller than the proximal end of the second portion (the location proximal to the proximal fluid guide).

In connection with particular embodiments, the cross-sectional area of the second portion of the internal longitudinal channel may be constant from the distal end of the second portion to the proximal end of the second portion. In such embodiments, the area of the constant cross-sectional area of the second portion of the inner longitudinal channel may be greater than the area of the cross-sectional area at the distal end of the second portion of the inner longitudinal channel.

Where the cross-section of the inner longitudinal channel of the fluid guide expands from the distal end to the proximal end, the cross-sectional expansion of the inner longitudinal channel generally comprises a gradual expansion in the cross-sectional area of the inner longitudinal channel from the distal end of the second portion to the proximal end of the fluid guide. Preferably, the expansion of the diameter of the inner longitudinal channel may be linear from the distal end of the proximal end of the second portion, e.g. frustoconical in shape. A linear reduction in cross-sectional area, such as a frustoconical shape, is advantageous for creating a smooth flow of fluid through the fluid guide.

Alternatively, the shrinkage is non-uniform. For example, in certain embodiments, the expansion of the inner longitudinal channel is stepped, with the cross-sectional area of the inner longitudinal channel contracting in discrete increments or steps from the distal end to the proximal end. The non-uniform reduction in cross-sectional area of the internal longitudinal passage is beneficial in creating turbulence in the fluid as it passes along the fluid guide

The proximal end of the inner longitudinal channel is typically between 0.5 mm and 3 mm in diameter, for example 0.8 mm, 1 mm, or preferably 1.2 mm.

The distal end of the inner longitudinal channel is typically between 1 and 5 mm in diameter, for example 1.2 mm, 2 mm, or preferably 2.2 mm.

The ratio of the diameter of the proximal end of the inner longitudinal channel to the diameter of the distal end of the inner longitudinal channel is typically between 1:4 and 3:4, or between 2:5 and 3:5, or preferably 1:2.

The distance between the proximal end and the distal end of the inner longitudinal channel may be any suitable distance. For example, the length of the inner longitudinal channel is typically 3 to 15 mm, such as 4 to 7 mm, or preferably 5.2 to 5.8 mm.

In particular embodiments of the present invention, the fluid guide may be modular, comprising two or more segments forming the fluid guide.

In combination with specific embodiments, the aerosol-generating article comprises at least one external longitudinal channel in communication with the aperture of the wrapper. In connection with certain embodiments, the channel is at least partially formed by a wrapper, wherein the wrapper is present. The channels direct fluid (e.g., ambient air) from the aperture toward the tubular element containing the active agent. In a specific embodiment, the outer longitudinal channel is formed outside the fluid guide below the inner surface of the wrapper.

The aerosol-generating article may comprise more than one external longitudinal channel. In a specific embodiment, the aerosol-generating article comprises 2 to 20 external longitudinal channels in the exterior of the fluid guide. For example, the article may comprise from 6 to 14 external longitudinal channels, typically from 10 to 12 channels. Different numbers of channels allow different aerosol flow dynamics.

Preferably, each external longitudinal channel communicates with at least one aperture through the wrapper. However, the aerosol-generating article may comprise one or more external longitudinal channels which are not in direct communication with the aperture. Preferably, each external longitudinal channel communicates with at least one aperture through an outer wall of the fluid guide. Where present, preferably the aperture through the wrapper and the aperture through the outer wall of the fluid guide are aligned with each other and at least one external longitudinal channel so as to allow fluid to flow into the aerosol-generating article and along the external longitudinal channel towards the distal end of the aerosol-generating article.

Preferably, the outer longitudinal channel and the wrap comprise more than one hole. For example, in combination with specific embodiments, the outer longitudinal channel and wrap are comprised between 2 and 20 holes. Preferably, the number of holes is equal to the number of outer longitudinal channels, and each hole corresponds to a separate outer longitudinal channel. Preferably, the apertures are evenly spaced, circumferentially disposed about the article, to even aid in the distribution of the fluid.

In combination with a specific embodiment, the side wall of the outer longitudinal channel extends along at least a portion of the longitudinal length of the aerosol-generating article between the exterior of the fluid guide and the interior side of the wrapper. For example, in certain embodiments, the fluid guide has longitudinal vanes with wraps present forming an outer longitudinal channel.

In connection with particular embodiments, the outer longitudinal channel extends completely around the interior of the wrapper. Alternatively, the outer longitudinal channel extends less than entirely around the circumference of the fluid guide, e.g. less than 90% around the circumference of the fluid guide, less than 70% around the circumference of the fluid guide, or less than 50% around the circumference of the fluid guide. In particular embodiments, the outer longitudinal channel extends at least 5% around the circumference of the fluid guide.

In combination with a specific embodiment, the distal end of the outer longitudinal channel is spaced apart from the distal end of the aerosol-generating article. Alternatively, in other embodiments, the distal end of the outer longitudinal channel is equal to the distal end of the fluid guide. In connection with certain embodiments, the distal end of the outer longitudinal channel may be 2 to 20 mm from the distal end of the aerosol-generating article, e.g. 10 and 12 mm from the distal end of the aerosol-generating article.

In connection with particular embodiments, the width of the outer longitudinal channel is, for example, between 0.5 and 2 millimeters, typically between 0.75 and 1.8 millimeters.

The distal end of the longitudinal channel may be positioned a distance from the distal end of the aerosol-generating article such that fluid entering the bore of the outer longitudinal channel may contact the tubular element and be capable of generating or releasing an aerosol from the gel. The aerosol generated or released at the tubular element may pass through the internal longitudinal channel of the fluid guide to the proximal end of the aerosol-generating article.

Preferably, at least 5% of the fluid flowing through the aerosol-generating article contacts the tubular element and the gel, preferably comprising an active agent. More preferably, at least 25% of the air flowing through the article contacts the tubular element containing the active agent.

In particular embodiments, not all of the fluid will be in contact with the tubular element, e.g., at least 5% of the fluid flowing through the aerosol-generating article will not be in contact with the tubular element, although in other particular embodiments this may be at least 10% of the fluid flowing through the aerosol-generating article.

In combination with a specific embodiment, the distal end of the fluid guide is spaced apart from the distal end of the aerosol-generating article. In connection with a specific embodiment, the distal end of the fluid guide may be 2 to 20 mm from the distal end of the aerosol-generating article, for example 7 to 17 mm, preferably 12 to 16 mm from the distal end of the aerosol-generating article.

Preferably, the aerosol-generating article is generally cylindrical. This facilitates smooth flow of the aerosol. The aerosol-generating article may have an outer diameter of, for example, between 4 mm and 15 mm, between 5 mm and 10 mm, or between 6 mm and 8 mm. The aerosol-generating article may have a length of, for example, between 10 mm and 60 mm, between 15 mm and 50 mm, or between 20 mm and 45 mm.

The Resistance To Draw (RTD) of the aerosol-generating article will vary depending on the length and size of the passageway, the size of the aperture, the size of the narrowest cross-sectional area of the internal passageway, the material used, and the like. In particular embodiments, the aerosol-generating article has an RTD of from 50 millimeters per water to 140 millimeters per water (mm H ₂ O), between 60 mm per water and 120 mm per water (mm H) ₂ O), or between 80 mm per water and 100 mm per water (mm H) ₂ O) between. RTD of an article refers to the difference in static pressure between one or more apertures of the article and the mouth end of the article when the article is traversed by the internal longitudinal passageway under steady conditions at which the volumetric flow rate at the mouth end is 17.5 ml/sec. The RTD of a sample can be measured using the method specified in ISO standard 6565:2002.

Preferably, the aerosol-generating article according to the invention comprises apertures at positions along the outer longitudinal channel. Thus, the orifice is located at a position upstream of the restrictor. In particular embodiments, the apertures will be provided as a row or row of apertures through the wrapper, or the fluid guide, or both the fluid guide and the wrapper, and allow fluid to be drawn into the aerosol-generating article. Before passing along the inner longitudinal channel and through the limiter (if present in this embodiment), the fluid is first sucked out of the aperture, then out of the outer longitudinal channel and then directed to the distal end of the aerosol-generating article, where the fluid may be in contact with the tubular element, preferably with the gel within the tubular element, preferably with the gel comprising the active agent. Preferably, the total internal path of fluid from the aperture to the proximal end of the aerosol-generating article is at least 9 mm. More preferably at least 10 mm, in order to provide optimal aerosol formation in terms of suction resistance and cooling effect.

By adjusting the number and size of the apertures, the amount of fluid entering the aerosol-generating article can be tailored to the stretching. For example, one or two rows of holes may be formed through the wrapper to allow easy fluid flow into the aerosol-generating article. In alternative embodiments, the wrap includes fewer holes, such as 2 or 4. The pore size and the number of pore sizes will affect the flow of fluid into the aerosol-generating article. Different combinations of Resistance To Draw (RTD) and fluid inflow into the aerosol-generating article may result in different aerosol formations, thus providing a wider design option for the aerosol-generating article according to the invention.

In particular embodiments, the aerosol-generating article comprises a plastic material, a metal material, a cellulosic material (such as cellulose acetate), paper, cardboard, cotton, or a combination thereof.

In particular embodiments, the fluid guide comprises a plastic material, a metal material, a cellulosic material (such as cellulose acetate), paper, cardboard, or a combination thereof.

In combination with particular embodiments, the package comprises more than one material. In particular embodiments, the package or a portion thereof comprises a metallic material, a plastic material, cardboard, paper, cotton, or a combination thereof. When the package comprises cardboard or paper, the holes may be formed by laser cutting.

The wrapper provides strength and structural rigidity to the aerosol-generating article. When paper or paperboard is used for the wrapper and a high degree of rigidity is required, it preferably has a basis weight of greater than 60 grams per square meter. One such package may provide a higher structural rigidity. The wrapper may resist deformation on the exterior of the aerosol-generating article at a location where the limiter (if present) is embedded within the aerosol-generating article or in other locations (e.g., where there is less structurally supported cavity (if present)). In some embodiments, the tubular element wrapper comprises a metal layer. The metal layer may be used to concentrate externally applied energy to heat the tubular member, e.g., the metal layer may act as a receiver of an electromagnetic field or collect radiant energy provided by an external heat source. The metal layer may prevent heat from leaving the tubular element through the wrapper if an internal heat source is present, thereby improving the heating efficiency. It may also provide uniform heat distribution along the periphery of the tubular member.

In a specific embodiment, the aerosol-generating article comprises a seal between the exterior of the fluid guide and the interior of the wrapper. The wrapper may then be securely attached to the fluid guide. It is not required to create a fluid impermeable seal.

In particular embodiments, the aerosol-generating article comprises a mouthpiece. The mouthpiece may comprise a fluid guide or a portion thereof and may form at least a proximal portion of a wrapper of the aerosol-generating article. The mouthpiece may be connected to the package or the distal portion of the package in any suitable manner, such as by an interference fit, threaded engagement, or the like. The mouthpiece may be part of the aerosol-generating article that may include a filter, or in some cases the mouthpiece may be defined by the extent of the tipping paper (if present). In other embodiments, the mouthpiece may be defined as a portion of an article that extends 40 millimeters from the mouth end of the aerosol-generating article or 30 millimeters from the mouth end of the aerosol-generating article.

The tubular element, preferably comprising a gel comprising an active agent, may place the aerosol-generating article proximally and distally prior to final assembly of the aerosol-generating article.

Once fully assembled, the aerosol-generating article defines a fluid path through which fluid may flow. When negative pressure is provided at the mouth end (proximal end) of the aerosol-generating article, fluid enters the aerosol-generating article through the aperture (or the fluid guide, or both) in the wrapper and then flows through the external longitudinal channel towards the distal end of the aerosol-generating article. It may entrain aerosol, optionally generated by heating the tubular element containing the active agent. The fluid entrained with the aerosol may then flow through the internal longitudinal channel of the fluid guide and through the open mouth end of the aerosol-generating article.

Preferably, the aerosol-generating article is configured to be received by the aerosol-generating device such that a heating element of the aerosol-generating device may heat a portion of the aerosol-generating article comprising the tubular element. For example, if the tubular element preferably comprises a gel comprising an active agent, the tubular element may be the distal end of the aerosol-generating article, the tubular element being disposed at or near the distal end of the aerosol-generating article.

Preferably, the shape and size of the aerosol-generating article may be used with a suitable, correspondingly shaped and sized aerosol-generating device comprising a container for containing the aerosol-generating article and a heating element configured and positioned to heat a section of the aerosol-generating article comprising: preferably comprising a tubular element comprising a gel of an active agent.

The aerosol-generating device preferably comprises control electronics operatively coupled to the heating element. The control electronics may be configured to control heating of the heating element. The control electronics may be inside the housing of the device.

The control electronics may be provided in any suitable form and may, for example, comprise a controller or memory and a controller. The controller may include one or more of the following: an application specific integrated circuit (Application Specific Integrated Circuit; ASIC), a state machine, a digital signal processor, a gate array, a microprocessor, or equivalent discrete or integrated logic circuits. The control electronics may include a memory containing instructions that cause one or more components of the circuit to implement the functions or aspects of the control electronics. The functions attributable to the control electronics in the present disclosure may be embodied as one or more of software, firmware, and hardware.

The electronic circuit may comprise a microprocessor, which may be a programmable microprocessor. The electronic circuit may be configured to regulate the supply of power to the heating element. The power may be supplied to the heating element in the form of current pulses. The control electronics may be configured to monitor the resistance of the heating element and control the supply of electrical power to the heating element in dependence on the resistance of the heating element. In this way, the control electronics can adjust the temperature of the resistive element.

The aerosol-generating device may comprise a temperature sensor, such as a thermocouple, operatively coupled to the control electronics to control the temperature of the heating element. The temperature sensor may be positioned at any suitable location. For example, the temperature sensor may be in contact with or in proximity to the heating element. The sensor may send a signal regarding the sensed temperature to control electronics, which may adjust the heating of the heating element to achieve the appropriate temperature at the sensor.

Whether or not the aerosol-generating device comprises a temperature sensor, the device may be configured to heat the tubular element, which preferably comprises a gel of the active agent contained in the aerosol-generating article to an extent sufficient to generate an aerosol.

The control electronics may be operably coupled to a power source, which may be internal to the housing. The aerosol-generating device may comprise any suitable power source. For example, the power source of the aerosol-generating device may be a battery or a battery pack. The battery or power supply unit may be rechargeable, as well as removable and replaceable.

In connection with particular embodiments, the heating element comprises a resistive heating element, such as one or more resistive wires or other resistive elements. The resistive wire may be in contact with the thermally conductive material to distribute the generated heat over a wider area. Examples of suitable conductive materials include gold, aluminum, copper, zinc, nickel, silver, and combinations thereof. Preferably, if the resistive wire is in contact with the thermally conductive material, both the resistive wire and the thermally conductive material are part of the heating element.

In combination with specific embodiments, the heating element includes a cavity configured to receive and surround a distal end of the article. The heating element may comprise an elongate element configured to extend along a side of the housing of the article when the distal end of the article is received by the device.

Alternatively, to insert the heating element into the aerosol-generating article, heat may be applied outside the tubular element with a heat jacket, which is thermally coupled around the wrapper of the aerosol-generating article. Preferably, the jacket is located in a portion of the aerosol-generating article comprising the tubular element.

In other embodiments, the heating element comprises inductive heating.

In a specific embodiment, the tubular element preferably comprises a gel, preferably comprising an active agent, heated by induction heating.

Preferably, the portion of the aerosol-generating article comprising the tubular element is positioned in the aerosol-generating device such that the one or more heating elements generating electromagnetic radiation for induction heating are in close proximity to the portion of the aerosol-generating article comprising the tubular element. Thus, preferably, the heating element of the aerosol-generating device is close to the gel within the aerosol-generating article when positioned in the aerosol-generating device.

Preferably, in an embodiment for induction heating, the aerosol-generating article comprises a susceptor. Preferably, in an embodiment for induction heating, the tubular element comprises a susceptor. Further preferably, in particular embodiments, the gel comprises a susceptor. Preferably, the susceptor is in contact with or close to the gel. Thus, in such embodiments of the invention, heat transfer can be readily applied to the gel upon heating the susceptor by radiation, releasing materials, such as active agents, from the gel.

Additionally or alternatively, in combination with other features of the invention, the gel-loaded porous medium comprises a susceptor. Thus, the susceptor can be in contact with the gel-loaded porous medium and allow the gel-loaded porous medium to be easily heated.

In particular embodiments, the gel within the tubular element may initially separate from the aerosol received into the tubular element and may be released to become entrained into the aerosol in response to the rupture of the frangible partition. Optionally, in certain embodiments, in use, portions of the gel may be sealed over the respective frangible separator and a suitable number of frangible zones need to be ruptured to achieve a desired level of active agent in the aerosol received into the tubular element into the aerosol.

In connection with particular embodiments, the aerosol-generating device may be configured to receive more than one aerosol-generating article described herein. For example, the aerosol-generating device may comprise a receptacle into which the elongate heating element extends. One aerosol-generating article may be contained on the container on one side of the heating element and another aerosol-generating article may be contained in the container on the other side of the heating element. Or in other embodiments, the aerosol-generating device comprises more than one recipient. Thus, more than one aerosol-generating article can be received at a time.

In connection with embodiments of the present invention, the wrap or a portion of the wrap is waterproof or hydrophobic, thereby having a degree of water repellency, or resistance to moisture penetration. This may be a wrapper of the tubular element, or a wrapper of the aerosol-generating article, or a wrapper of both the tubular element and the aerosol-generating article. It may also be a wrapper of any other part of the aerosol-generating article, or any other component of the aerosol-generating article, including the longitudinal side of the second tubular element within the first tubular element. The wrap may be naturally impermeable, thereby resisting water or moisture penetration. The wrap may be multi-layered with a barrier to prevent or reduce the passage of water, or at least resist the penetration of water or moisture. The hydrophobic barrier or hydrophobic treatment using the wrapper in combination with a particular embodiment may be over the entire area of the wrapper. Alternatively, in other embodiments, the hydrophobic barrier or treatment of the wrapper is part of the wrapper, for example, this may be one side of the wrapper, the inside or outside of the wrapper; or may be treated on both sides of the wrapper.

The hydrophobic region of the wrapper may be prepared by a method comprising the steps of: a liquid composition comprising a fatty acid halide is applied to at least one surface of the wrapper and held for about 5 minutes at a temperature of 120 degrees celsius to 180 degrees celsius. The fatty acid halide reacts in situ with the proton donating groups of the material in the wrapper, resulting in the formation of fatty acid esters, thereby imparting hydrophobic properties and resistance to moisture penetration.

It is contemplated that the hydrophobically treated wrapper may reduce or prevent water, moisture or liquid adsorption or transfer to or from the wrapper. Advantageously, the hydrophobically treated wrapper does not negatively affect the taste of the article.

In certain embodiments, the wrapper in use generally forms the exterior of the aerosol-generating article. In particular embodiments, the wrap comprises: paper, homogenized tobacco impregnated paper, homogenized tobacco, wood pulp, hemp, flax, straw, esparto grass, eucalyptus, cotton, etc. In particular embodiments, the substrate or paper forming the wrapper has a substrate or paper basis weight, and the range of wrapper formation is in the range of 10 to 50 grams per square meter, for example 15 to 45 grams per square meter. In connection with particular embodiments, the thickness of the substrate or paper forming the wrapper is in the range of 10 to 100 microns or preferably 30 to 70 microns.

In accordance with specific embodiments, the hydrophobic groups are covalently bonded to the inner surface of the wrapper. In other embodiments, the hydrophobic group is covalently bonded to the outer surface of the wrapper. It has been found that covalent typing of hydrophobic groups into one side or surface of the wrapper imparts hydrophobic properties to the opposite side or surface of the wrapper. Hydrophobic wraps or hydrophobically treated wraps may reduce or prevent fluids, such as liquid fragrances or liquid release components, from becoming soiled or absorbed or transmitted through the wraps.

In various embodiments, the wrap, particularly the packaging region adjacent to the tubular element of the active agent containing gel, is hydrophobic or has one or more hydrophobic regions. Such hydrophobic or hydrophobically treated wraps may have a Cobb water absorption (ISO 535:1991) value (at 60 seconds) of less than 40g/m ² Less than 35g/m ² Less than 30g/m ² Or less than 25g/m ² 。

In various embodiments, the wrap, particularly the packaging region adjacent to the tubular element comprising the active agent, preferably comprises a gel having a water contact angle of at least 90 degrees, such as at least 95 degrees, at least 100 degrees, at least 110 degrees, at least 120 degrees, at least 130 degrees, at least 140 degrees, at least 150 degrees, at least 160 degrees, or at least 170 degrees. Hydrophobicity was determined by using TAPPI T558 om-97 test and the results are presented as interface contact angles and reported in degrees and can range from near zero degrees to near 180 degrees. When the contact angle is not specified along with the term hydrophobic, the water contact angle is at least 90 degrees.

In connection with particular embodiments, the hydrophobic surface is present uniformly along the length of the package, or in other particular embodiments, the hydrophobic surface is present uniformly along the length of the package.

Preferably, the wrapper is formed from any suitable cellulosic material, preferably the cellulosic material is derived from a plant. In many embodiments, the wrap is formed from a material having pendant proton donating groups. Preferably, the proton donating group is a reactive hydrophilic group such as, but not limited to, hydroxyl (-OH), amine (-NH) ₂ ) Or mercapto (-SH) ₂ )。

A particularly suitable wrap suitable for use in the present invention will now be described by way of example. Packaging materials with side hydroxyl groups include cellulosic materials such as paper, wood, textile, natural and man-made fibers. The wrapper may also include one or more filler materials, such as calcium carbonate, carboxymethyl cellulose, potassium citrate, sodium acetate, or activated carbon.

The hydrophobic surface or region of the cellulosic material forming the wrapper may be formed with any suitable hydrophobic agent or hydrophobic group. The hydrophobic agent is preferably chemically bonded to the cellulosic material forming the wrapper, or to a proton donating side group of the cellulosic material. In many embodiments, the hydrophobic agent is covalently bonded to the cellulosic material or proton donating side groups of the cellulosic material. For example, hydrophobic groups are covalently bonded to the side hydroxyl groups of the cellulosic material forming the wrapper. Covalent bonds between the structural components of the cellulosic material and the hydrophobic agent may form hydrophobic groups that are more firmly attached to the paper material rather than simply providing a coating of hydrophobic material on the cellulosic material forming the wrapper. Chemically bonding the hydrophobic agent at the molecular level in situ, rather than applying a layer of bulk to cover the surface, allows the permeability of the cellulosic material, such as paper, to better hold because the coating tends to cover or block the pores of the cellulosic material forming a continuous sheet and reduce the permeability. Chemically binding the hydrophobe to the paper in situ can also reduce the amount of material required to make the wrapper surface. The term "in situ" as used herein refers to the location of chemical reactions that occur on or near the surface of the solid material forming the wrapper, which may be different from the reaction of cellulose dissolved in solution. For example, the reaction occurs at or near the surface of the cellulosic material forming the wrapper, which includes the cellulosic material in an heterogeneous structure. However, the term "in situ" does not require that the chemical reaction occur directly on the cellulosic material forming the hydrophobic region.

The hydrophobic agent may comprise an acyl or fatty acid group. The acyl or fatty acid groups or mixtures thereof may be saturated or unsaturated. The fatty acid groups (e.g., fatty acid halides) in the reactants can react with proton donating side groups (e.g., hydroxyl groups) of the cellulosic material to form ester linkages that chemically bond the fatty acids to the cellulosic material. In general, these reactions with hydroxyl side groups can esterify cellulosic materials.

In one embodiment of the wrapper, the acyl or fatty acid group comprises C ₁₂ -C ₃₀ Alkyl (alkyl having 12 to 30 carbon atoms), C ₁₄ -C ₂₄ Alkyl (alkyl having 14 to 24 carbon atoms) or preferably C ₁₆ -C ₂₀ Alkyl (alkyl having 16 to 20 carbon atoms). It will be appreciated by those skilled in the art that the term "fatty acid" as used herein refers to long chain aliphatic, saturated or unsaturated fatty acids comprising 12 to 30 carbon atoms, 14 to 24 carbon atoms, 16 to 20 carbon atoms, or having greater than 15, 16, 17, 18, 19 or 20 carbon atoms. In various embodiments, the hydrophobic agent comprises an acyl halide, such as a fatty acyl chloride comprising, for example, palmitoyl chloride, stearoyl chloride, or benzoyl chloride, or mixtures thereof. The in situ reaction between the fatty acid chloride and the cellulosic material forming the continuous sheet produces fatty acid esters of cellulose and hydrochloric acid.

Any suitable method may be used to chemically bond the hydrophobic agent or group to the cellulosic material forming the hydrophobic region. Hydrophobic groups are covalently bonded to the cellulosic material by diffusion of fatty acyl halides onto the surface of the cellulosic material without the use of solvents.

As one example, a hydrophobic agent, such as an acyl halide, fatty acid chloride, palmitoyl chloride, stearoyl chloride or chloride, mixtures thereof, is deposited without solvent (solventless process) onto the surface of the coated paper at a controlled temperature, e.g., to form droplets of 20 microns of the agent on the surface. Control of the vapor tension of the reagent may promote reaction propagation by diffusion as ester bonds are formed between the fatty acid and the cellulose while continuously removing unreacted acid chloride. In some cases, the esterification reaction of cellulose is based on the reaction of an alcohol group or a pendant hydroxyl group of cellulose with an acyl halide compound (e.g., fatty acid chloride). The temperature at which the hydrophobic reagent may be heated depends on the chemistry of the reagent and the fatty acid halide, which ranges from, for example, 120 degrees celsius to 180 degrees celsius.

The hydrophobic agent may be applied to the cellulosic material of the wrapper in any useful amount or basis weight. In many embodiments, the basis weight of the hydrophobic agent is less than 3 grams per square meter, less than 2 grams per square meter, or less than 1 gram per square meter, or in the range of 0.1 to 3 grams per square meter, 0.1 to 2 grams per square meter, or 0.1 to 1 gram per square meter. The hydrophobic agent may be applied or printed on the wrapper surface and define a uniform or non-uniform pattern.

Preferably, the hydrophobic tube regions are formed by reacting fatty acid ester groups or fatty acid groups with pendant hydroxyl groups on the cellulosic material of the wrapper paper to form fatty acid ester groups or fatty acid groups to form a hydrophobic surface. This reaction step may be accomplished by applying a fatty acid halide (e.g., chloride) that provides a fatty acid or fatty acid group to chemically bond with the side hydroxyl groups on the cellulosic material of the wrapper to form a hydrophobic surface. The application step may be performed by loading the fatty acyl halide in liquid form on a solid support (such as a brush, roller, or absorbent or non-absorbent pad) and then contacting the solid support with the surface of the paper. The fatty acid halides can also be applied by printing techniques (e.g., gravure, flexographic, inkjet, solar offset), by spraying, by wetting, or by dipping in a liquid comprising the fatty acid halide. The applying step may deposit discrete islands of the agent to form a uniform or non-uniform pattern of hydrophobic regions on the surface of the wrapper. The uniform or non-uniform pattern of hydrophobic regions on the wrapper paper may be formed of at least 100 discrete hydrophobic islands, at least 500 discrete hydrophobic islands, at least 1000 discrete hydrophobic islands, or at least 5000 discrete hydrophobic islands. The discrete hydrophobic islands may have any useful shape, such as circular, rectangular or polygonal. Discontinuous hydrophobic islands may have any useful average lateral dimension. In many embodiments, the discontinuous hydrophobic islands have an average lateral dimension in the range of 5 to 100 microns, or in the range of 5 to 50 microns. To assist in the diffusion of the applied agent over the surface, an air flow may also be applied to the surface of the wrapper.

In connection with particular embodiments, the hydrophobic wrapper may be prepared by a method comprising applying a liquid composition comprising an aliphatic acid halide (preferably a fatty acid halide) to at least one surface of the wrapper, optionally applying a gas stream to the wrapper on the surface to aid in diffusing the applied fatty acid halide and holding for at least 5 minutes at a temperature of 120 degrees celsius to 180 degrees celsius, wherein the fatty acid halide reacts with cellulosic material in the wrapper resulting in the formation of a fatty acid ester. Preferably, the wrapper is made of paper and the fatty acid halide is benzoyl chloride, palmitoyl chloride, or a mixture of fatty acid chlorides having 16 to 20 carbon atoms in the acyl group. Thus, the hydrophobic wrapper paper prepared by the method described above can be distinguished from a material prepared by coating a surface with a pre-made fatty acid ester of cellulose.

The hydrophobic wrap paper may be prepared by the following process: the liquid reagent composition is applied to at least one surface of the wrapper at a rate in the range of 0.1 to 3 grams per square meter, or 0.1 to 2 grams per square meter, or 0.1 to 1 gram per square meter. The liquid agent applied at these rates renders the wrapping paper hydrophobic surface.

In many embodiments, the thickness of the wrapper allows hydrophobic groups or agents to be applied to one surface to provide substantially similar hydrophobic properties to both opposing surfaces. In one example, the wrapper paper has a thickness of 43 microns and is rendered hydrophobic by a gravure (printing) process using stearoyl chloride as the hydrophobic agent to a gravure of one surface.

In some embodiments, the material or method to create the hydrophobic properties of the hydrophobic region does not substantially affect the permeability of the wrap in other regions. Preferably, the agent or method of creating the hydrophobic region alters the permeability of the wrapper in the treated region (as compared to the untreated packaging region) by less than 10% or less than 5% or less than 1%.

In many embodiments, the hydrophobic surface may be formed by printing an agent along the length of the cellulosic material. Any useful printing method may be utilized, such as gravure, ink jet, or the like. Gravure printing is preferred. The agent may comprise any useful hydrophobic group which may be chemically, e.g. covalently, bound to the wrapper, in particular the cellulosic material of the wrapper or a pendant group of the cellulosic material.

In combination with specific embodiments of the invention, the aerosol-generating article comprises a susceptor. In combination with specific embodiments, the tubular element comprises a susceptor. Preferably, the susceptor is elongated and longitudinally arranged within the tubular element, preferably the susceptor is in thermal contact with the gel or gel-loaded porous material. This may assist in heat transfer from the heating element in the aerosol-generating device and through the aerosol-generating article, preferably through the tubular element, to the susceptor, so that the gel or porous medium is in the vicinity of the gene. When the heating is by induction heating, the fluctuating electromagnetic field is transferred through the aerosol-generating article, preferably through the tubular element, to the susceptor, such that the susceptor changes the nearby fluctuating field to thermal energy, thereby heating the gel or the porous material loaded with the gel. Typically, the susceptor has a thickness of 10 to 500 microns. In a preferred embodiment, the susceptor has a thickness of between 10 and 100 microns. Alternatively, the susceptor may be in the form of a powder dispersed within a gel. Typically, susceptors are configured to dissipate 1 to 8 watts of energy, for example, 1.5 to 6 watts, when used with a particular inductor. By configuration, it is meant that the elongated susceptor may be manufactured from a specific material and may have a specific size that allows for an energy consumption of between 1 and 8 watts when used in combination with a specific conductor generating a fluctuating magnetic field of known frequency and known field strength.

According to a further aspect of the present invention there is provided an aerosol-generating system comprising an electrically powered aerosol-generating device having an inductor for producing an alternating or fluctuating electromagnetic field, and an aerosol-generating article comprising a susceptor as described and defined herein. The aerosol-generating article is engaged with the aerosol-generating device such that the fluctuating electromagnetic field generated by the inductor induces an electrical current in the susceptor, causing the susceptor to warm. The electric aerosol-generating device is preferably capable of generating a fluctuating electromagnetic field having a magnetic field strength (type H strength) of 1 kiloamp per meter to 5 kiloamps per meter (kA/m), preferably 2 kiloamps per meter to 3 kiloamps per meter (kA/m), for example 2.5 kiloamps per meter (kA/m). The electrically powered aerosol-generating device is preferably capable of generating a fluctuating electromagnetic field having a frequency of 1 megahertz (MHz) to 30 MHz, for example between 1 MHz and 10 MHz, for example between 5 MHz and 7 MHz.

Preferably, the elongate susceptor of the present invention is part of a consumable and is therefore used only once. As the new susceptor is used to heat each aerosol-generating article, the flavour of a series of aerosol-generating articles may be more consistent. The requirement for cleaning aerosol-generating devices is significantly easier for devices with reusable heating elements and can be achieved without damaging the heat source. Furthermore, the lack of a heating element that is required to penetrate the aerosol-forming substrate means that insertion and removal of the aerosol-generating article into and from the aerosol-generating device is less likely to result in inadvertent damage to the aerosol-generating article or the aerosol-growing device. Thus, the overall aerosol-generating system is robust.

Eddy currents induced in the susceptor when the susceptor is positioned within a fluctuating electromagnetic field can cause the susceptor to heat. Desirably, the susceptor is positioned in thermal contact with the gel of the tubular member or the gel-loaded porous material, and therefore the gel or the gel-loaded porous material, or both the gel and the gel-loaded porous material, are heated by the susceptor.

In connection with particular embodiments, the aerosol-generating article is designed to be engaged by an electrically-powered aerosol-generating device comprising an inductively-heated source. An inductive heating source or inductor generates a fluctuating electromagnetic field for heating a susceptor located within the fluctuating electromagnetic field. In use, the aerosol-generating article is engaged with the aerosol-generating device such that the susceptor is located within the fluctuating electromagnetic field generated by the inductor.

Preferably, the susceptor has a length dimension greater than its width dimension or its thickness dimension, for example greater than twice its width dimension or its thickness dimension. Thus, the susceptor may be described as an elongated susceptor. Such susceptors are arranged substantially longitudinally within the rod. This means that the length dimension of the elongate susceptor is arranged substantially parallel to the longitudinal direction of the aerosol-generating article, for example within plus or minus 10 degrees of the longitudinal axis with respect to the longitudinal direction of the rod. In a preferred embodiment, the elongate susceptor element may be positioned at a radially central position within the aerosol-generating article and extend along a longitudinal axis of the aerosol-generating article.

The susceptor is preferably in the form of a pin, rod, strip, sheet or vane. The length of the elongated susceptor element is preferably between 5 and 15 mm, for example between 6 and 12 mm, or between 8 and 10 mm. Typically, the susceptor is at least as long as the tubular element and thus typically is between 20% and 120% of the longitudinal length of the tubular element, for example between 50% and 120% of the length of the tubular element, preferably between 80% and 120% of the longitudinal length of the tubular element. The susceptor preferably has a width of between 1 and 5 mm and may have a thickness of between 0.01 and 2 mm, for example between 0.5 and 2 mm. The thickness of the preferred embodiment may be between 10 and 500 microns, or even more preferably between 10 and 100 microns. If the susceptor element has a constant cross-section, for example a circular cross-section, it preferably has a width or diameter of between 1 and 5 mm.

The susceptor may be formed of any material capable of being inductively heated to a temperature sufficient to generate an aerosol from the aerosol-forming substrate. In a preferred embodiment, the susceptor comprises metal or carbon. Preferred susceptors may comprise ferromagnetic materials, such as ferritic iron or ferromagnetic steel or stainless steel. In other embodiments, the susceptor comprises aluminum. Preferred susceptors may be made of 400 series stainless steel, for example grade 410 or grade 420 or grade 430 stainless steel. When positioned within an electromagnetic field having similar frequency and field strength values, different materials will consume different amounts of energy. Thus, parameters of the susceptor, such as material type, length, width and thickness, can be altered within the known electromagnetic field to provide the desired power consumption.

Preferably, the susceptor is heated to a temperature in excess of 250 degrees celsius. Preferably, however, the susceptor is heated to less than 350 degrees celsius to prevent combustion of the material in contact with the susceptor. Suitable susceptors may include a nonmetallic core with a metal layer disposed on the nonmetallic core, such as a metal trace formed on a surface of a ceramic core.

The susceptor may have an outer protective layer, such as a ceramic protective layer or a glass protective layer, that encapsulates the elongated susceptor. The susceptor may include a protective coating formed of glass, ceramic, or an inert metal formed on a core of susceptor material.

Preferably, the susceptor is arranged in thermal contact with the aerosol-forming substrate, for example within the tubular element. Thus, when the susceptor is heated, the aerosol-forming substrate is heated and material is released from the gel to form an aerosol. Preferably, the susceptor is arranged in direct physical contact with the gel comprising the active agent, e.g. within the tubular element, the susceptor preferably being surrounded by the gel or a porous medium loaded with the gel.

In a specific embodiment, the aerosol-generating article or tubular element comprises a single susceptor. Alternatively, in other specific embodiments, the tubular element or aerosol-generating article comprises more than one susceptor.

Any of the features described herein in relation to a particular embodiment, aspect or example of a tubular element, an aerosol-generating article or an aerosol-generating device may equally be applied to any embodiment of a tubular element, an aerosol-generating article or an aerosol-generating device.

Drawings

Reference will now be made to the drawings, which depict one or more aspects described in the present disclosure. However, it should be understood that other aspects not depicted in the drawings fall within the scope of the present disclosure. Like numbers used in the figures refer to like parts, steps, etc. It will be appreciated, however, that the use of a number in a given figure to refer to one component is not intended to limit the component labeled with the same number in another figure. In addition, the use of different numbers to refer to components in different figures is not intended to indicate that the differently numbered components cannot be the same or similar to other numbered components. The drawings are presented for purposes of illustration and not limitation. The schematic diagrams presented in the figures are not necessarily drawn to scale.

Fig. 1 is a schematic cross-sectional view of an aerosol-generating device and a schematic side view of an aerosol-generating article that may be inserted into the aerosol-generating device.

Fig. 2 is a schematic cross-sectional view of the aerosol-generating device depicted in fig. 1 and a schematic side view of the article depicted in fig. 1 inserted into the aerosol-generating device.

Fig. 3-6 are schematic cross-sectional views of various embodiments of aerosol-generating articles.

Fig. 7 is a schematic side view of an aerosol-generating article.

Fig. 8 is a schematic perspective view of the embodiment of the aerosol-generating article depicted in fig. 7, with a portion of the wrapper removed for illustration purposes.

Fig. 9 is a schematic side view of an aerosol-generating article.

Fig. 10 is a schematic side view of the embodiment of the aerosol-generating article depicted in fig. 9, with a portion of the wrapper removed.

Fig. 11 is a schematic view of a fluid guide of a sample aerosol-generating article.

Fig. 12 is a schematic view of a sample aerosol-generating article with the fluid guide depicted in fig. 11 inserted therein.

Fig. 13 shows a cross-sectional view taken along the length of an aerosol-generating article.

Fig. 14, 15 and 16 show perspective and two cross-sectional views of a tubular element for an aerosol-generating article.

Fig. 17 shows a part of a manufacturing process for a tubular element of an aerosol-generating article.

Fig. 18 shows a part of a further manufacturing process of a tubular element for an aerosol-generating article.

Fig. 19 shows a part of an alternative manufacturing process for a tubular element of an aerosol-generating article.

Fig. 20 shows an aerosol-generating system comprising an electrically heated aerosol-generating device and an aerosol-generating article.

Fig. 21, 22 and 23 show cross-sectional views of further tubular elements for an aerosol-generating article.

Fig. 24 shows a cross-sectional view along the length of the aerosol-generating article.

Figures 25-29 show schematic cross-sectional views of various tubular elements.

Fig. 30-34 show schematic cross-sectional views of various tubular elements.

Fig. 35 shows a perspective view of a schematic of a tubular element comprising a wire loaded with gel.

Fig. 36 shows a cross-sectional view (from proximal to distal) of a schematic view of the tubular element shown in fig. 35.

Fig. 37 shows a cross-sectional view of the tubular element shown in fig. 35.

Fig. 38 shows a cross-sectional view of the tubular element.

Fig. 39 shows a cross-sectional view of the tubular element.

Detailed Description

Fig. 1-6 show longitudinal cross-sectional views of an aerosol-generating article 100. In other words, fig. 1 to 6 show longitudinal half-cut views of the aerosol-generating article 100. In the embodiments of fig. 1 to 6, the aerosol-generating article is tubular. If the entire end face of the aerosol-generating article 100 of fig. 1 to 6 is observed, the proximal end 101 or the distal end 103 will be rounded. The tubular element 500, if used or shown in the embodiments of fig. 1-6, is tubular. The tubular element 500 is a possible tubular part of the tubular aerosol-generating article 100 of the embodiment of fig. 1 to 6. If the entire end face of the tubular element 500, whether proximal or distal, used and shown in the embodiments of fig. 1-6 were observed, the face of the tubular element would be circular. Since fig. 1 to 6 are two-dimensional longitudinal cross-sectional views, the aerosol-generating article and the lateral curvature of the tubular element 600 are not visible, among other components. The drawings are for illustrative purposes of the invention and may not be to scale. The tubular element 500 is used to illustrate the tubular element 500 in the aerosol-generating article 100 if shown in fig. 1-6, but the features of the aerosol-generating article 100 are optional to the embodiment shown for the tubular element 500 and should not be considered as essential features of the tubular element 500.

Figures 1 to 2 serve the purpose of illustrating how the tubular element of the present invention is used in an aerosol-generating article and how the aerosol-generating article is used with an aerosol-generating device. The details of the tubular element are not shown in detail in these figures.

Fig. 1-2 show examples of an aerosol-generating article 100 and an aerosol-generating device 200. The aerosol-generating article 100 has a proximal or mouth end 101 and a distal end 103. In fig. 2, the distal end 103 of the aerosol-generating article 100 is received in a container 220 of the aerosol-generating device 200. The aerosol-generating device 200 comprises a wrapper 110 defining a container 220 configured to receive the aerosol-generating article 100. The aerosol-generating device 200 further comprises a heating element 230 forming a cavity 235 configured to receive the aerosol-generating article 100, preferably by interference fit. The heating element 230 may include a resistive heating component. In addition, the apparatus 200 includes a power supply 240 and control electronics 250 that cooperate to control the heating of the heating element 230.

The heating element 230 may heat the distal end 103 of the aerosol-generating article 100 comprising the tubular element 500 (not shown). In this embodiment, the tubular element 500 comprises a gel 124 comprising an active agent comprising nicotine. The heating of the aerosol-generating article 100 causes the tubular element 500 comprising the gel 124 (the gel comprising the active agent) to generate an active agent-containing aerosol, which may be delivered out of the aerosol-generating article 100 at the proximal end 101. The aerosol-generating device 200 comprises a housing 210.

The exact heating mechanism is not shown in fig. 1-2.

In some examples, the heating mechanism may be by conduction heating, wherein heat is transferred from the heating element 230 of the aerosol-generating device 200 to the aerosol-generating article 100. This can easily occur when the aerosol-generating article 100 is positioned in the container 220 and distal end 103 of the aerosol-generating device 200 (which is preferably the end at which the gel-containing tubular element 500 is located) and thus the aerosol-generating article 100 is in contact with the heating element 230 of the aerosol-generating device 200. In a specific example, the heating element comprises a heating blade protruding from the aerosol-generating device 200 and adapted to penetrate into the aerosol-generating article 100 to be in direct contact with the gel 124 of the tubular element 500.

In this example, the heating mechanism is by induction, wherein the heating element emits wireless electromagnetic radiation that is absorbed by the tubular element when the aerosol-generating article 100 is positioned in the container 220 of the aerosol-generating device 200.

Figures 3a to 13 show an aerosol-generating article or a part of an aerosol-generating article suitable for use in the tubular element of the invention. All details of the tubular element are not necessarily shown or marked in these figures 3a to 13.

Fig. 3a and 3b depict one embodiment of an aerosol-generating article 100 comprising a wrapper 110 and a fluid guide 400. Fig. 3a and 3b are longitudinal cross-sectional views of the aerosol-generating article 100. In other words, the views of fig. 3a and 3b are longitudinal half cut aerosol-generating articles 100. In the embodiment of fig. 3a and 3b, the aerosol-generating article is tubular. If the entire end face of the aerosol-generating article 100 of fig. 3a or 3b is observed, the proximal end 101 or the distal end 103 will be rounded. The tubular element 500 in fig. 3a or 3b is also tubular. The tubular element 500 is a tubular part of the tubular aerosol-generating article 100 of the embodiment of fig. 3a and 3 b. If the entire end face of the tubular element 500 of the embodiment of fig. 3a or 3b, whether proximal or distal, is viewed, the face of the tubular element will be rounded. Because fig. 3a and 3b are two-dimensional longitudinal cross-sectional cut views, the aerosol-generating article and the lateral curvature of the tubular element 600 are not visible, except for other components. In fig. 3a, the proximal end of the tubular element 500 is not shown as having a straight edge. Fig. 3b shows the proximal end of the tubular element 500 as a straight line across the width of the aerosol-generating article. The drawings are for illustrative purposes of the invention and may not be to scale. The tubular element 500 is shown in fig. 3a and 3b to illustrate the tubular element in an aerosol-generating article, but the features of the aerosol-generating article 100 are optional to the embodiment of the tubular element as shown and should not be regarded as essential features of the tubular element 500.

The fluid guide 400 has a proximal end 401, a distal end 403, and an internal longitudinal passageway 430 from the distal end 403 to the proximal end 401. The inner longitudinal passageway 430 has a first portion 410 and a second portion 420. The first portion 410 defines a first portion of the passageway 430 that extends from a distal end 413 of the first portion 410 to a proximal end 411 of the first portion 410. The second portion 420 defines a second portion of the passageway 430 that extends from the distal end 423 of the second portion 420 to the proximal end 421 of the second portion 420. The first portion 410 of the channel 430 has a constricted cross-sectional area moving from the distal end 413 to the proximal end 411 of the first portion 410, thereby accelerating fluid (e.g. air) through the first portion 410 of the inner longitudinal channel 430 when a negative pressure is applied at the proximal end 101 of the aerosol-generating article 100. The cross-sectional area of the first portion 410 of the internal longitudinal passageway 430 narrows from the distal end 413 to the proximal end 411 of the first portion 410. The second portion 420 of the inner longitudinal passageway 430 has a cross-sectional area that expands from the distal end 423 to the proximal end 421 of the second portion 420 of the fluid guide 400. In the second portion 420 of the inner longitudinal passage 430, the fluid may slow down.

The wrapper 110 defines an open proximal end 101 and a distal end 103 of the aerosol-generating article 100. A tubular element 500 comprising a gel (comprising an active agent, not shown) is disposed in the distal end 103 of the aerosol-generating article 100. The aerosol-generating article 100 comprises an end plug 600 at its distal-most end 103. End plug 600 is located at the distal end of tubular member 500. End plug 600 comprises a high resistance to suction material to thereby bias fluid into aerosol-generating article 100 through aperture 150 upon application of negative pressure to proximal end 101 of aerosol-generating article 100. The aerosol generated or released from the tubular element 500 containing the active agent may, when heated, enter the cavity 140 in the aerosol-generating article downstream of the tubular element 500 to be carried through the internal longitudinal channel 430.

The aperture 150 extends through the wrapper 110. At least one aperture 150 communicates with an external longitudinal passageway 440 formed between an outer surface of the fluid guide 400 and an inner surface of the wrapper 110. At a location between the aperture 150 and the proximal end 101, a seal is formed between the fluid guide 400 and the package 110.

When negative pressure is applied to the proximal end 101 of the aerosol-generating article 100, fluid enters the aperture 150, flows through the outer longitudinal channel 440 into the lumen 140 and the tubular element 500 comprising a gel (gel comprising an active agent), wherein the fluid may entrain the aerosol when the tubular element 500 comprising a gel (gel comprising an active agent) is heated. The fluid then flows through the interior longitudinal channel 430 and through the proximal end 101 of the aerosol-generating article 100. As the fluid flows through the first portion 410 of the inner longitudinal passageway 430, the fluid accelerates. As the fluid flows through the second portion of the internal longitudinal passageway 430, the fluid decelerates. In the depicted embodiment, the wrapper 110 defines a proximal cavity 130 between the proximal end 401 of the fluid guide 400 and the proximal end 101 of the article 100, which may be used to slow down the fluid prior to exiting the mouth end 101.

Fig. 4 depicts one embodiment of an aerosol-generating article 100 comprising a wrapper 110 and a fluid guide 400.

The fluid guide 400 has a proximal end 401, a distal end 403, and an internal longitudinal passageway 430 from the distal end 403 to the proximal end 401. The interior longitudinal channel 430 has a first portion 410, a second portion 420, and a third portion 435. The first portion 410 is between the second portion 420 and the third portion 435. The first portion 410 defines a first portion of the interior longitudinal channel 430 that extends from a distal end 413 of the first portion 410 to a proximal end 411 of the first portion 410. The second portion 420 defines a second portion of the interior longitudinal channel 430 that extends from a distal end 423 of the second portion 420 to a proximal end 421 of the second portion 420. The third portion 435 defines a third portion of the interior longitudinal channel 430 that extends from a distal end 433 of the third portion to a proximal end 431 of the third portion. The third portion 435 has a substantially constant inner diameter from the proximal end 431 to the distal end 433. The first portion 410 of the inner longitudinal channel 430 has a constricted cross-sectional area moving from the distal end 413 to the proximal end 411 of the first portion 410, thereby accelerating the fluid through the first portion 410 of the inner longitudinal channel 430 when a negative pressure is applied at the proximal end 101 of the aerosol-generating article 100. The cross-sectional area of the first portion 410 of the interior longitudinal channel 430 narrows from the distal end 413 to the proximal end 411 of the first portion 410. The second portion 420 of the inner longitudinal channel 430 has a cross-sectional area that expands from the distal end 423 to the proximal end 421 of the second portion 420 of the inner fluid channel 430. In the second portion 420 of the inner longitudinal channel 430, the fluid may decelerate as it travels in a direction from distal to proximal.

Similar to the article 100 depicted in fig. 3, the article depicted in fig. 4 includes a wrap 110 defining an opening, a proximal end 101 and a distal end 103, with a high suction resistance end plug 600. A tubular element 500 comprising a gel (the gel comprising an active agent) is provided in the distal end 103 of the aerosol-generating article. When heated, the aerosol released from the active agent-containing gel may be carried through the internal longitudinal channel 430 into the cavity 140 in the aerosol-generating article 110.

Although not shown in fig. 4, the aerosol-generating article 100 includes at least one aperture (such as aperture 150 shown in fig. 3) extending through the wrapper 110 and in communication with an external longitudinal channel 440 formed between the outer surface of the fluid guide 400 and the inner surface of the wrapper 110. At a location between the aperture and the distal end 101, a seal is formed between the fluid guide 400 and the wrap 110. While the seal need not be fluid impermeable, it is advantageous that the seal herein does have a high resistance to aspiration or a degree of impermeability so that the fluid entering bore 150 is biased along the outer longitudinal channel in a distal direction toward tubular member 500. The third portion 435 of the fluid guide 400 extends the length of the fluid guide 400 and the outer longitudinal channel 440 to provide additional distance between the aperture (not shown in fig. 4, which may be located near the proximal end 401 of the inner longitudinal channel) and the gel-containing tubular element 500 such that the gel containing the active agent may not leak through the aperture 150.

When negative pressure is applied at the proximal end 101 of the aerosol-generating article 100 depicted in fig. 4, fluid enters the aperture 150, flows through the outer longitudinal channel 440 into the lumen 140 and the gel-containing tubular element 500 (gel contains active agent), wherein the fluid may entrain material from the heated active agent-containing gel. The fluid may then flow through the inner longitudinal channel 430 and through the proximal end 101 of the aerosol-generating article. As the fluid flows through the inner longitudinal channel 430, the fluid flows through the third portion 435, the first portion 410, and then through the second portion 420 of the aerosol-generating article 100. As the fluid flows through the first portion 410 of the inner longitudinal passageway 430, the fluid accelerates. As the fluid flows through the second portion 420 of the inner longitudinal channel 430, the fluid decelerates. In alternative embodiments, the second portion 420 and the third portion 435 of the interior longitudinal channel 430 are optional. In the depicted embodiment, the wrap defines a proximal cavity 130 between the proximal end 401 of the fluid guide 400 and the proximal end 101 of the article 100, which may be used to slow down the fluid prior to exiting the proximal end 101.

Fig. 5 and 6 depict further embodiments of an aerosol-generating article 100 comprising a wrapper 110, an end plug 600, a tubular element 500 comprising a gel (the gel comprising an active agent), a proximal lumen 130, a lumen 140, and a fluid guide 400. The fluid guide 400 has a proximal end 401, a distal end 403, and an internal longitudinal passageway 430 from the distal end 403 to the proximal end 401. The interior longitudinal channel 430 has a first portion 410 and a second portion 435. The first portion 410 defines a first portion 410 of the interior longitudinal channel 430 that extends from a distal end 413 of the first portion 410 to a proximal end 411 of the first portion 410. The third portion 435 defines a third portion of the interior longitudinal channel 430 that extends from a proximal end 433 of the third portion 435 to a distal end 431 of the third portion 435. Third portion 435 has a substantially constant inner diameter from proximal end 433 to distal end 431.

In fig. 5, the first portion 410 of the inner longitudinal channel 430 has a substantially constant inner diameter from the distal end 413 to the proximal end 411 of the first portion 410. The inner diameter of the inner longitudinal channel 430 at the first portion 410 is smaller than the inner diameter of the inner longitudinal channel 430 at the third portion 435. The restricted inner diameter of the interior longitudinal passage 430 at the first portion 410 relative to the third portion 435 may cause the fluid to accelerate as it flows from the third portion 435 to the first portion 410.

In fig. 6, a first portion 410 of the fluid guide 400 includes a plurality of sections 410A, 410B, 410C having a stepped inner diameter. The most distal section 410A has the largest inner diameter and the most proximal section 410C has the smallest inner diameter. As fluid flows through the internal longitudinal channel 430 from the first section 410A to the second section 401B and from the second section 410B to the third section 410C, the fluid may accelerate as the cross-sectional area of the internal longitudinal channel 430 contracts in a stepped fashion.

The first portion 410 in fig. 5 and 6 provides an example of a configuration that may be beneficial when the material used to form the first portion 410 is not readily moldable. For example, the first portion 410 or segments 410A, 410B, 410C of the first portion 410 may be formed from cellulose acetate tow. In contrast, the first portion 410 of the fluid guide 400 depicted in fig. 3 and 4 provides an example of a configuration that may be beneficial when the material used to form the first portion 410 is moldable, such as when the first portion is formed from, for example, polyetheretherketone (PEEK).

Similar to the aerosol-generating article 100 depicted in fig. 3 and 4, the aerosol-generating article depicted in fig. 5 and 6 comprises a wrapper 110 defining an opening, a proximal end 101 and a distal end 103 having an end plug 600, the end plug 600 having a high resistance to suction. In these examples including a gel 124 (the gel including an active agent), a tubular element 500 is disposed in the distal end 103 of the aerosol-generating article 100. Aerosol released from the tubular element 500 containing the sol 124 (sol containing active agent) when heated may enter the cavity 140 in the aerosol-generating article 100 to be carried through the internal longitudinal channel 430.

Although not shown in fig. 5 and 6, the aerosol-generating article 100 includes at least one aperture (e.g., aperture 150 shown in fig. 3) extending through the wrapper 110 and in communication with an external longitudinal channel 440 formed between an outer surface of the fluid guide 400 and an inner surface of the wrapper 110. A seal is formed between the fluid guide 400 and the wrap 110 at a location between the one or more apertures 150 and the proximal end 101. This helps to bias fluid into the pass-through bore 150 along the outer longitudinal channel 440 or distal direction in the tubular member 500. The third portion 435 of the inner longitudinal channel 430 serves, among other things, to extend the length of the fluid guide 400 and the outer longitudinal channel 440 to provide an additional distance between the aperture 150 (which is not shown in fig. 5 and 6, and which may be located near the proximal end of the outer longitudinal channel 440) and the tubular element 500 containing the gel 124 (the gel contains the active agent) such that the gel 124 containing the active agent may not leak through the aperture 150.

When negative pressure is applied at the proximal end 101 of the aerosol-generating article 100 depicted in fig. 5 and 6, the fluid enters the aperture 150, flows into the lumen 140 through the outer longitudinal channel 440 to the tubular element 500 containing the gel 124 (the gel contains the active agent), wherein the fluid may entrain substances from the gel when the tubular element 500 is heated. The fluid may then flow through the inner longitudinal channel 430 and through the proximal end 101. As the fluid flows through the inner longitudinal channel 430, the fluid flows through the third portion 435 and then through the first portion 410 of the aerosol-generating article 100. When fluid flows into the first portion 410 of the inner longitudinal channel 430, the inner longitudinal channel 430 may accelerate because the inner diameter of the inner longitudinal channel 430 at the first portion 410 is smaller than at the third portion 435. In the aerosol-generating article 100 depicted in fig. 6, the fluid may accelerate as it passes through each section 410A, 410B, 410C of the first portion 410.

In the embodiment shown in fig. 4 and 5, the wrap defines a cavity 130 between the proximal end 401 of the fluid guide 400 and the proximal end 101 of the aerosol-generating article 100, which may be used to slow down liquid exiting the internal longitudinal channel 430 at the proximal end 401 of the fluid guide 400 before exiting the proximal end 101.

Fig. 7-8 illustrate embodiments of an aerosol-generating article 100. The aerosol-generating article 100 comprises a wrapper 110 and an aperture 150 through the wrapper 110. The aerosol-generating article comprises an end plug 600 forming the distal end 103 of the aerosol-generating article 100. The end plug has a high resistance to suction. A tubular element 500 comprising a gel (the gel comprising an active agent) is provided proximal to an end plug 600 in an aerosol-generating article 100. When heated, the tubular element 500 may form an aerosol that enters the lumen 140 proximal of the tubular element 500.

Fig. 7 shows a side view of the tubular aerosol-generating article 100. If the face of the proximal end 101 or distal end 103 is viewed, the end face will be rounded. Fig. 7 is a two-dimensional view, and thus the curvature of the tubular aerosol-generating article cannot be seen. Fig. 8 is a partial cutaway perspective view of the same embodiment shown and described in fig. 7. Although partially blocked, it can be seen that the distal face is rounded. Although partially cut away, it can be seen that the face of the proximal end 101 will also be rounded. As can also be seen in fig. 8, the tubular element 500 is tubular. Also as can be seen in fig. 8, for this embodiment, end cap 600 is also tubular.

At least one of the apertures 150 communicates with at least one external longitudinal channel 440 formed between the fluid guide 400 and the wrap 110 and with the sidewall 450. The fluid guide 400 has a rim 460 that presses against the inner surface of the wrap 110 to form a seal. A seal is formed between proximal end 101 and bore 150.

When negative pressure is applied at the proximal end 101, a fluid, such as air, may enter the bore 150 and flow through the outer longitudinal channel 440 to the lumen 140 and then through the tubular member 500, wherein material from the gel 124 is released into the fluid. The fluid then travels through the fluid guide 400, through the interior longitudinal channel 430, into the cavity 130 defined by the wrapper 110, and through (and out of) the proximal end 101 of the aerosol-generating article 100. The internal longitudinal channel 430 of the fluid guide 400 may be configured in any suitable manner, such as the examples shown in fig. 3-6.

Fig. 9-10 illustrate an embodiment of an aerosol-generating article 100 comprising a mouthpiece 170 forming part of a wrapper 110 and a fluid guide 400 of the aerosol-generating article 100. The aerosol-generating article 100 comprises a tubular element 500 forming the distal end 103 of the aerosol-generating article 100 and also being formed by a portion of the wrapper 110. The tubular element 500 is configured to be received by the distal portion of the mouthpiece 170, for example, by an interference fit. A tubular member containing a gel 124 (the gel containing an active agent, not shown) may be disposed in distal end 103. The aerosol-generating article 100 comprises an end plug 600 at the distal-most end 103. End plug 600 has high resistance to suction.

Fig. 9 shows a portion of a cross-sectional side view of a tubular aerosol of the article 100 being produced. If the entire face of the proximal end 101 or distal end 103 is to be viewed, the end face will be rounded. Fig. 9 is a two-dimensional view, and thus the curvature of the tubular aerosol-generating article cannot be seen. Fig. 10 is a partially cut-away perspective view of the same portion of the aerosol-generating article 100 shown and described in fig. 9. Although partially blocked, it can be seen that the distal face is rounded. Although partially cut away, it can be seen that the face of the proximal end 101 will also be rounded. As can also be seen in fig. 10, the tubular member 500 is tubular. Also as can be seen in fig. 10, for this embodiment, end cap 600 is also tubular.

The fluid guide 400 includes an internal longitudinal channel 430 (not shown) that includes portions that accelerate the fluid and may include portions that decelerate the fluid. A seal is formed between wrap 110 and fluid guide 400 because wrap 110 and fluid guide 400 are formed from a single piece. The aperture 150 is formed in the wrapper 110 and communicates with an external longitudinal channel 640 formed at least in part by the inner surface of the wrapper 110. A portion of the outer longitudinal channel 640 is generally formed between the inner surface of the wrap 110 and the exterior of the fluid guide 400. The outer longitudinal channel 640 extends less than the full distance around the article 100. In this embodiment, the outer longitudinal channel 640 surrounds about 50% of the distance around the circumference of the aerosol-generating article 100. The outer longitudinal channel 640 directs fluid (e.g., air) from the aperture 150 toward the tubular member 500 (not shown) near the distal end 103.

When negative pressure is applied at the proximal end 101, a fluid, such as ambient air, enters the aerosol-generating article 100 through the aperture 150. The fluid flows through the outer longitudinal channel 640 towards the tubular element 500, which contains the gel 124 containing the active agent disposed at the distal end 103. The fluid then flows through the internal longitudinal channel 430 of the fluid guide 400, wherein the fluid is accelerated and optionally decelerated. A fluid, such as air, may then leave the proximal end 101 of the aerosol-generating article 100.

Fig. 11 is an illustration of a fluid guide 400 formed from a Polyetheretherketone (PEEK) material by Computer Numerical Control (CNC) machining. The fluid guide 400 depicted in fig. 11 has a length of 25 millimeters, an outer diameter at the proximal end of 6.64 millimeters, and an outer diameter at the distal end of 6.29 millimeters. The outer diameter at the distal end is the diameter of the distal end from the base of the sidewall. The fluid guide 400 has 12 outer longitudinal channels 640 formed around the outer surface of the fluid guide, each side wall having a substantially semi-circular cross-sectional area. The outer longitudinal channel 640 has a radius of 0.75 mm and a length of 20 mm. The fluid guide 400 has an internal longitudinal channel 430 (not shown) comprising three sections, a first section (fluid accelerating section), a second section downstream or proximal to the first section (fluid decelerating section), and a third section upstream or distal to the first section. The third portion of the inner longitudinal channel 430 of the fluid guide 400 extends from the distal end 103 of the aerosol-generating article 100 and has an inner diameter at its distal end of 5.09 mm, which tapers to a diameter of 4.83 mm at the proximal end of the first portion of the inner longitudinal channel 430. The length of the first portion of the inner longitudinal channel is 15 mm. The first portion of the internal longitudinal channel 430 extends from the distal end at the proximal end of the third portion to the proximal end. The first portion of the inner longitudinal channel 430 has an inner diameter of 2 millimeters at its distal end, which tapers to 1 millimeter at its proximal end. The length of the first portion of the inner longitudinal channel is 5.5 millimeters. The second portion of the interior longitudinal channel 430 extends from a distal end at the proximal end of the first portion to a proximal end at the proximal end of the article. The second portion of the inner longitudinal channel 430 has an inner diameter of 1 millimeter at its distal end that is the same as the inner diameter at the proximal end of the first portion. The inner diameter of the second portion increases proximally at a decreasing rate (i.e., in a curve) with an inner diameter of 5 mm. The length of the second portion was 4.5 mm. Thus, fluid drawn proximally from the distal end through the internal passage of the fluid guide encounters a chamber having a substantially constant inner diameter (third portion), a constricted section (first portion) configured to accelerate the fluid, and an enlarged section (second portion) configured to decelerate the fluid. It has been found that providing such an internal longitudinal channel 430 for aerosol released from a heated tubular element 500 (not shown) allows for controlling the aerosol volume and droplet size such that a satisfactory aerosol is released. Fig. 11 is a side view of tubular fluid guide 400. Fig. 11 is a two-dimensional view of the tubular shape of the fluid guide 400 in this embodiment, and therefore curvature cannot be seen. If the end face of the fluid guide 400 of the present embodiment is viewed, the face will be circular.

Fig. 12 is an illustration of an assembled aerosol-generating article 100. The aerosol-generating article 100 comprises a wrapper 110 into which the fluid guide 400 of fig. 11 is inserted. The wrap depicted in fig. 12 is typically a cylindrical paper tube having a length of 45 millimeters. One end of wrap 110 is distal to provide a distal end of wrap for holding tubular element 500 (not shown). The diameter of the outer proximal portion of the fluid guide 400 above the outer longitudinal channel was 6.64 millimeters. The diameter is substantially the same as the inner diameter of the wrap such that an interference fit seal may be formed between the proximal portion of the exterior of the fluid guide 400 and the interior of the wrap 110. The distal portion of the outer portion of the fluid guide 400 extends the length of the outer longitudinal channel, may have a diameter slightly smaller than the diameter of the proximal portion of the outer portion of the fluid guide 400, such that the fluid guide may be easily inserted into the wrap 110 up to the proximal portion of the outer portion, wherein an interference fit is formed. Fig. 12 is a side view of the aerosol-generating article 100. Fig. 12 is a two-dimensional view of the tube shape of the aerosol-generating article 100 in this embodiment, and thus its curvature cannot be seen. If the end face of the aerosol-generating article 100 of this embodiment is viewed, the face will be rounded.

Fig. 13 shows an aerosol-generating article 100 manufactured from a tubular element 500 comprising a gel 124, which is further shown in fig. 14, 15 and 16. Fig. 13 is a longitudinal cross-sectional view of the aerosol-generating article 100. Fig. 13 is a two-dimensional view of the fluid guide 100 and its components (e.g., tubular element 500) in this embodiment, and thus the curvature of its tubular shape cannot be seen. If the entire end face of the aerosol-generating article 100 of this embodiment is viewed, the face will be rounded. Also, if the entire end face of the tubular element 500 of this embodiment is viewed, the face will be circular.

The aerosol-generating article 100 of fig. 13 comprises four elements arranged in coaxial alignment: a high resistance to suction (RTD) end plug 600 at distal end 103 includes tubular element 500 of gel 124, fluid guide 400 and mouthpiece 170 at proximal end 101. The four elements are arranged in sequence and surrounded by an overwrap 110 to form the aerosol-generating article 100. (in a similar but alternative embodiment, there is a lumen 140 between the fluid guide 400 and the tubular element 500.) the aerosol-generating article 100 has a proximal or mouth end 101, and a distal end 103 located at an opposite end of the aerosol-generating article 100 from the proximal end 101. Not all of the components of the tubular member 500 need be shown or labeled in fig. 13.

In use, when negative pressure is applied at the proximal end 101, a fluid, such as air, is drawn through the aerosol-generating article 100 (not shown, but similar to those described for the example of fig. 1-10) through the aperture 150.

End plug 600 is located at very distal end 103 of aerosol-generating article 100.

In this example, tubular element 500 is located immediately downstream of end plug 600 and abuts end plug 600.

In fig. 9, the distal end portion of the outer wrapper 110 of the aerosol-generating article 100 is surrounded by a tipping paper tape (not shown).

As further shown in fig. 14, 15 and 16, the tubular element 500 is a cellulose acetate tube 122 containing the gel 124 in a core, e.g., the core is filled with the gel 124. In this embodiment, the gel 124 comprises an active agent that is nicotine and an aerosol former. Other examples similar to this example include different active agents, or no active agents. Not all of the components of the tubular member 500 of fig. 14, 15 and 16 need be displayed or marked.

Fig. 14 shows a perspective view of the tubular element 500, fig. 15 shows a cross-sectional view coplanar with the central axis of the tubular element 500, and fig. 16 shows a cross-sectional view perpendicular to the central axis. Fig. 16 shows an end face of a tubular element 500.

The tubular element 500 is located in the aerosol-generating article 100 (fig. 13) at the distal end 103 of the aerosol-generating article 100 such that the tubular element 500 may be penetrated by a heating element of the aerosol-generating device 200, in this example penetrating the end plug 600 (at the very distal end 103 of the aerosol-generating article 100) to contact the tubular element 500 comprising the gel 124. Thus, the heating element contacts the gel 124 or is in close proximity to the gel 124.

Gel 124 contains an active agent that is released into a fluid, such as air, from aperture 150 along an external longitudinal channel (not shown) in fluid guide 400 to tubular member 500 near distal end 103 and then through internal longitudinal channel 430 to proximal end 101 (not shown). In this illustrative example, the active agent is nicotine. Optionally, the gel 124 also includes a flavor, such as menthol.

The tubular element 500 may additionally comprise a plasticizer.

The fluid guide 400 is located immediately downstream of the tubular element 500 and abuts the tubular element 500. (in a similar but alternative specific example, such as in fig. 24, there is a cavity between the fluid guide 400 and the tubular element 500, so the fluid guide does not contact the tubular element). In use, material released from the tubular element 500 containing the gel 124 is transferred along the fluid guide 400 towards the proximal end 101 of the aerosol-generating article 100.

In the example of fig. 13, the mouthpiece 170 is located immediately downstream of the fluid guide 400 and abuts the fluid guide 400. In the example of fig. 13, mouthpiece 170 comprises a conventional low filtration efficiency cellulose acetate tow filter.

To assemble the aerosol-generating article 100, the four elements described above are aligned and wrapped within the overwrap 110. In fig. 13, the overwrap is a conventional cigarette paper.

The tubular member 500 may be formed by an extrusion process, for example as shown in fig. 17. The longitudinal sides of the cellulose acetate 122 of the tubular member 500 may be formed by extruding the cellulose acetate material along the die 184 and around the mandrel 180 (which protrudes rearward relative to the direction of travel T of the extruded cellulose acetate material). The rear protrusion of the mandrel 180 is shaped as a pin and is a cylindrical member having an outer diameter of 3 to 7 mm and a length of 55 to 100 mm. (to assist in explanation, not illustrated to scale in the figures).

In this example, the cellulose acetate material 122 has a thermoset by exposure to steam S at a pressure greater than 1 bar.

The mandrel 180 is provided with a conduit 182 along which the gel 124 is extruded into a core of solidified cellulose acetate material 122, which in this example forms the longitudinal sides of the tubular element 500. In other examples, the cellulose acetate material 122 is thermoset prior to extruding the gel 124 into the core of the cellulose acetate material 122.

The composite cylindrical rod is cut to length to form individual tubular elements 500.

In this example a composite cylindrical rod is formed by a hot extrusion process. The composite cylindrical rod is cooled or subjected to a cooling process prior to being processed to length. Alternatively, in other examples, the composite cylindrical rod may be formed by a cold extrusion process.

In the illustrated tubular element 500 of this example, cellulose acetate 122 is shown as the longitudinal side of the tubular element 500 having a core that fills the gel 124. However, alternatively, in other examples, the longitudinal sides of the cellulose acetate 122 may have any shape, with a core (or more than one core), for receiving the gel 124 that generally extends along the tubular shaft. In an alternative embodiment, the core is filled with a porous medium 125 loaded with gel.

In this example, the minimum thickness of the longitudinal sides of the cellulose acetate 122 of the tubular member is 0.6 mm.

In the manufacturing process shown in fig. 17, the gel 124 is continuously extruded.

In an alternative example as shown in fig. 18, the gel 124 may be extruded in bursts (in burst) separated by gaps 128, as shown in fig. 18. In an alternative specific example, the gel-loaded porous medium 125 is extruded in bursts to have separation gaps in the core of the tubular rod.

The gel 124 may be heated above room temperature prior to injection into the mandrel 180. The mandrel 180 may be thermally conductive (e.g., a metal mandrel), as well as some externally applied heat applied to the thermoset of cellulose acetate (e.g., from steam S). This can transfer thermal energy into the gel, which can reduce its viscosity and facilitate its extrusion.

In an alternative specific example, as shown in fig. 19, the mandrel 180 is configured to reduce heating of the gel 124 prior to extrusion. In some of these specific examples, mandrel 180 is formed of a substantially thermally insulating material. Alternatively or additionally, the mandrel 180 is cooled, for example, by a jacket 186 with liquid cooling (e.g., a water-cooled jacket), a circulating layer of cooling liquid with a thermal barrier formed between externally applied heat (e.g., steam S) and the gel 124. Maintaining the gel 124 at a low temperature may facilitate forming the gel 124 within the longitudinal sides of the cellulose acetate 122 of the tubular member 500.

In this example, the tubular element 500 is formed by cutting through the gap 128 of the composite rod, which helps to prevent the gel 124 from contaminating the cutting machine, thereby improving cutting performance. In this example, the composite rod is cooled through rest for a period of time until a suitable cutting temperature is reached prior to cutting. After cutting, if cut into the gap 128 (which in some examples is trimmed to form a tubular element) and prior to assembly into an aerosol to produce the article 100, the cut length has a hollow end. In this example, the bursts of gel 124 are 60 millimeters long and separated by a 10 millimeter gap. In other examples, the hollow ends are not trimmed at both ends to create a cavity 140 between the gel 124 and the fluid guide 400.

Instead of the illustrated example herein, in a specific example, the gel 124 may be extruded at room temperature. Furthermore, in alternative embodiments, the cellulose acetate is replaced by other materials, such as polylactic acid.

In fig. 19, the mandrel has a cylindrical shape to facilitate manufacturing of the tubular element.

Fig. 20 shows a portion of an aerosol-generating device 200 with a partially inserted aerosol-generating article 100, as described above and shown in fig. 13.

The aerosol-generating device 200 comprises a heating element 230. As shown in fig. 20, the heating element 230 is mounted within the aerosol-generating article 100 receiving chamber of the aerosol-generating device 200. In use, the aerosol-generating article 100 is inserted into the aerosol-generating article receiving chamber of the aerosol-generating device 200 such that the heating element 230 is inserted into the tubular element 500 of the aerosol-generating article 100 through the end plug 600, as shown in fig. 20. In fig. 20, the heating element 230 of the aerosol-generating device 200 is a heater blade.

The aerosol-generating device 200 comprises a power supply and electronics that allow the heating element 230 to be actuated. Such actuation may be manually operated or may occur automatically in response to a negative pressure applied at the proximal end of the aerosol-generating article 100 inserted into the aerosol-generating article receiving chamber of the aerosol-generating device 200. Providing a plurality of openings in the aerosol-generating device to allow air to flow to the aerosol-generating article 100; the direction of fluid, e.g. air, flow in the aerosol-generating device 200 is shown by the arrows in fig. 20. The fluid may then enter the aerosol-generating article 100 through the aperture 150, not shown.

Once the internal heating element 230 is inserted into the tubular element 500 of the aerosol-generating article 100 and actuated, the tubular element 500 containing the gel 124 (gel containing active agent) is heated to a temperature of 375 degrees celsius by the heating element 230 of the aerosol-generating device 200. At this temperature, the material from the tubular element 500 of the aerosol-generating article 100 leaves the gel. When negative pressure is applied to the proximal end 101 of the aerosol-generating article 100, this material from the tubular element 500 is drawn downstream through the aerosol-generating article 100, in particular through the fluid guide 400 towards the proximal end and away from the proximal end 101 of the aerosol-generating article 100.

As the aerosol passes thoroughly downstream through the aerosol-generating article 100, the temperature of the aerosol decreases as thermal energy is transferred from the aerosol to the fluid guide 400. In this example, the temperature of the aerosol is approximately 150 degrees celsius when the aerosol enters the fluid guide 400. Due to the cooling within the fluid guide 400, the temperature of the aerosol is 40 degrees celsius as it exits the fluid guide 400. This results in the formation of aerosol droplets.

In the illustrated example of fig. 20, the tubular element 500 comprises cellulose acetate, which forms the longitudinal sides 122 of the cylindrical rod, with the gel 124 in the core or central portion of the tubular element 500. Alternatively, in other specific examples, the longitudinal sides of the tubular element 500 may be cardboard; wrinkled paper such as wrinkled heat-resistant paper or wrinkled parchment paper; or a polymeric material such as Low Density Polyethylene (LDPE).

In fig. 14, 15, 16, the tubular element 500 has a single core provided with a single gel 124, wherein the gel 124 fills the core, surrounded by cellulose acetate along the longitudinal sides of the tubular element 500. However, in alternative specific examples, the tubular element 500 includes more than one core. In particular embodiments, the tubular element includes more than one gel 124. Not all of the components of the tubular member 500 of fig. 14, 15 and 16 need be displayed or marked.

As shown in the example of fig. 21, the tubular element 500 includes a plurality of gels 524A, 524B extending along the axial length of the core of the tubular element 500, as shown in cross-section in fig. 21. In this embodiment, the tubular member 500 includes cellulose acetate longitudinal sides 522, 622, 722. Not all of the components of the tubular member 500 need be shown or labeled in the embodiment of fig. 21.

The various gels 524A, 524B may be extruded into the cellulose acetate 522 through separate conduits (not shown) in the mandrel forming the core of the tubular member 500. The use of gels 124 having different volatilities may facilitate optimization of delivery of the active agent.

In the example shown in fig. 22, the tubular element 500 includes a cellulose acetate longitudinal side 622, the tubular element 500 additionally including a plurality of cores 624A, 624B, 624C, as shown in cross-section in fig. 22.

Not all of the components of the tubular member 500 need be shown or labeled in this embodiment of fig. 22.

In this particular example, the multiple cores are provided with different gels 624A, 624B, 624C having different active agents, such as different nicotine and flavoring agents, as shown in fig. 22. The use of gels with different volatilities may facilitate optimizing the delivery of the active ingredient, in particular during the time of the heating cycle of the aerosol-generating device.

In other specific examples (not shown), each of the plurality of cores 624A, 624B, 624C is provided with the same gel 124 (not shown). The use of multiple cores helps to optimize air flow performance through the tubular member 500.

The plurality of cores may be formed by using a mandrel (not shown) having a corresponding plurality of protrusions extending rearward relative to the direction of travel T of the extruded cellulose acetate material. The gel may be extruded through a respective conduit of the plurality of rearwardly extending mandrel projections.

In fig. 14, 15, 16, the tubular member 500 includes a longitudinal side core of cellulose acetate 122 filled with gel 124 in the core. However, alternatively, in combination with other features in a specific example, the core of the tubular element 500 is only partially filled with gel 124 in a cross section perpendicular to the axial length. Advantageously, this facilitates axial air flow through the length of the tubular element 500. For example, as shown in fig. 23, the gel 724 may be provided in the form of a coating on the inner face of the longitudinal side of the tubular element 500. Not all of the components of the tubular member 500 need be shown or labeled in the embodiment of fig. 23.

In this illustrated example, i.e., the embodiment of fig. 23, tubular element 500 has a hollow conduit 726 extending axially along its length, by using a mandrel (not shown) with a central rod extending further downstream into the tube where gel 724 is extruded during the manufacturing process to form a hollow conduit within extruded gel 724.

Although fig. 20 shows an aerosol-generating article 100 for use with a leaf-like heating element 230 of an aerosol-generating device 200, the tubular element 500 may alternatively be used in other aerosol-generating articles 100 that are heated in a different manner.

For example, fig. 24 shows a cross-sectional view of an example of an aerosol-generating device 100 suitable for induction heating as well as heating with a blade-like heating element. Fig. 24 shows an example of an aerosol-generating article 100 suitable for use in the tubular element of the present invention. Fig. 24 is a cross-sectional view of a tubular aerosol-generating article and components thereof, such as the tubular element 500, and thus does not show the curvature of the tubular shape. Not all of the components of the tubular member 500 need be shown or labeled in this fig. 24.

In the example of fig. 24, the aerosol-generating article 100 comprises, in order from proximal to distal, a mouthpiece 170 at the proximal end 101, a fluid guide 400, a cavity 700, a tubular element 500 and an end plug 600. In this example, tubular element 500 contains gel 824 (gel contains an active agent), and also includes a susceptor (both not shown). The susceptor in this example is a single aluminum strip centered along the longitudinal axis of the tubular element 500. Upon insertion of the distal end 103 of the aerosol-generating article 100 into the aerosol-generating device 200 (not shown), the portion of the aerosol-generating article 100 comprising the tubular element 500 is caused to be positioned adjacent to the induction heating element 230 (not shown) of the aerosol-generating device 200 (not shown). When negative pressure is applied to the proximal end 101 of the aerosol-generating article 100, electromagnetic radiation generated by the inductive heating element 230 is absorbed by the susceptor and helps to heat the gel 824 in the tubular element 500, thereby helping to release material from the gel 824, such as active agent entrained in the delivered aerosol. Fluid (e.g., air) enters the outer longitudinal channel 834 through the aperture 150 (not shown) before returning to the lumen for delivery to the lumen 700 and then to the tubular member 500, wherein the fluid mixes with the gel 824 and becomes entrained with the active agent and then passes through the inner longitudinal channel (not shown) of the fluid guide 400 before exiting the proximal end 101. In this example, the longitudinal side 822 of the tubular element 500 comprises paper. The aerosol-generating article comprises an outer wrapper 850. The aerosol-generating article 100 as shown and described in fig. 24 may be used in an aerosol-generating device 200 as shown and described in fig. 1-2. Preferably, the aerosol-generating article 100 of fig. 16 is heated by induction from the aerosol-generating device 200.

The tubular element 500 may have many different combinations in other aspects; gel 124, porous media 125 loaded with gel, active agent, internal longitudinal elements, void spaces, filler material (preferably porous), and wrap. The desired aerosol may be produced by a specific combination and arrangement of its components.

For example:

fig. 25 shows an example in which a tubular element 500 comprises: a wrapper 110; a second tubular element 115, the second tubular element 115 comprising a gel 124, the second tubular element 115 comprising a paper wrap, the second tubular element being centered along a longitudinal axis of the tubular element 500; a porous filler material 132 positioned between the second tubular member 115 and the wrap 110. The porous filler material 132 helps to hold the second tubular element centrally within the tubular element 500. The gel 124 in this example is located within a central portion of the second tubular element 115.

Fig. 26 shows an example in which a tubular element 500 includes: a wrapper 110; a second tubular element 115 containing gel 124, the second tubular element comprising a paper wrap, the second tubular element being centered along the longitudinal axis of tubular element 500; a gel 124 located between the second tubular element 115 and the wrap 110. The gel located between the second tubular element 115 and the wrap 110 helps to keep the second tubular element 115 centered within the tubular element 500. The gel 124 in this example is located within the central portion of the second tubular element 115, and between the second tubular element 115 and the wrap 110.

Fig. 27 shows an example in which a tubular element 500 comprises: a wrapper 110; an inner longitudinal member comprising a gel-loaded porous medium 125, the inner longitudinal member comprising the gel-loaded porous medium 125 centered along a longitudinal axis of the tubular member 500; gel 124, which is located between the inner longitudinal element comprising gel-loaded porous medium 125 and wrap 110. The gel 124 may help to retain an inner longitudinal member comprising a porous medium loaded with the gel 124, centered within the tubular member 500. In this example, the inner longitudinal element is transverse in longitudinal cross-section and a portion of the inner longitudinal element contacts the inner surface of wrap 110. Other examples may use other shapes and sizes of internal longitudinal elements, and thus may not necessarily contact the inner surface of wrap 110. Other specific examples may also use internal longitudinal elements of different materials.

Fig. 28 shows an example in which a tubular element 500 includes: a wrapper 110; a second tubular element 115 containing a gel 124, the second tubular element 115 comprising a paper wrap, the second tubular element being centered along the longitudinal axis of the tubular element 500; a porous medium loaded with gel 124, which is located between the second tubular element 115 and the wrap 110. In this example, the porous medium loaded with gel 124 helps to keep the second tubular element 115 centered within the tubular element 500.

Fig. 29 shows an example in which a tubular element 500 comprises: a wrapper 110; a porous medium 125 loaded with gel; and a gel 124; a porous medium 125, in which the gel is loaded, is located near the inner surface of wrap 110 and surrounds gel 124. In this example, there is a gel 124 and a porous medium 125 loaded with the gel. The gel-loaded porous medium 125 coats the inner surface of the wrapper, however, the gel-loaded porous medium 125 may be first formed in shape and then wrapped by the wrapper 110. In this example, the gel-loaded porous medium 125 is surrounded by a gel 124, which is centrally maintained along the longitudinal axis of the tubular element 500. The gel-loaded porous medium may help retain the gel 125 along a central location.

Fig. 30 shows an example in which a tubular element 500 comprises: a wrapper 110; a second tubular member 115 comprising a porous medium 125 loaded with gel, the second tubular member 115 comprising a paper wrapper; the second tubular element 115 is centered along the longitudinal axis of the tubular element 500; a porous filler material 132 positioned between the second tubular member 115 and the wrap 110. The porous filler material 132 helps to hold the second tubular element centrally within the tubular element 500. In this example, the gel-loaded porous medium 125 is located within a central portion of the second tubular element 115. In this example, the paper wrapper of the second tubular element 115 surrounds the porous medium loaded with gel.

Fig. 31 shows an example in which a tubular element 500 comprises: a wrapper 110; a second tubular element 115 comprising a porous medium 125 loaded with gel, the second tubular element 115 being centered along the longitudinal axis of the tubular element 500, the second tubular element further comprising a paper wrapper; a gel-loaded porous medium 125 located between the second tubular element 115 and the wrap 110. In this example, the gel-loaded porous medium 125 is in two locations within the second tubular element 115 and between the second tubular element and the wrap 110. These may have the same or different porous media, gels or active agents.

Fig. 32 shows an example in which a tubular element 500 includes: a wrapper 110; a second tubular element 115 comprising a porous filler material 132, the second tubular element 115 being centered along the longitudinal axis of the tubular element 500, the second tubular element 115 further comprising a paper wrapper; a gel-loaded porous medium 125 is located between the second tubular member 115 and the wrap 110. The gel-loaded porous medium may help to centrally retain the second tubular element 115 along the longitudinal axis of the tubular element 500. In this example, the gel-loaded porous medium 125 is adjacent to the inner surface of the wrap 110. The gel-loaded porous medium 125 coats the inner surface of the wrap 110.

Fig. 33 shows an example in which a tubular element 500 includes: a wrapper 110; a second tubular element 115 comprising a porous medium 125 loaded with gel, the second tubular element 115 being centered along the longitudinal axis of the tubular element 500, the second tubular element 115 further comprising a paper wrapper; gel 124 is located between second tubular member 115 and wrap 110. In this example, the gel 124 may help to centrally retain the second tubular element 115 along the longitudinal axis of the tubular element 500. In this example, gel 124 is adjacent to the inner surface of wrap 110. In this example, the porous medium loaded with gel 124 is centered within the second tubular element 115, surrounded by a paper wrapper of the second tubular element 115.

Fig. 34 shows an example in which a tubular element 500 includes: a wrapper 110; an inner longitudinal element comprising gel-loaded porous medium 125, the inner longitudinal element comprising gel-loaded porous medium 125 being cylindrical, centered along the longitudinal axis of tubular element 500; a gel 124 located between the inner longitudinal element comprising the gel-loaded porous medium 125 and the wrap 110. The gel 124 may help to retain an inner longitudinal member comprising a porous medium loaded with the gel 124, centered within the tubular member 500. In this example, the inner longitudinal element is cylindrical in its longitudinal cross section and is kept separate from the inner surface of the wrapper 110 by the gel 124. Other examples may use other shapes and sizes of internal longitudinal elements and materials.

Fig. 35, 36 and 37 show a tubular element 500 comprising a wire 125 loaded with gel. In this example, gel loaded wire 125 extends longitudinally, substantially parallel to the longitudinal axis of tubular element 500. Advantageously, this creates a passage of aerosol through the longitudinal direction of the tubular element. In this example, there is a second tubular element 304 with an inner wrap 115 that is centered within the tubular element 500. The second tubular member 304 is also longitudinally positioned within the tubular member 500. The gel loaded wire 125 is positioned between the second tubular member 304 and the inner surface of the wrap 110. In the example shown in fig. 35, 36 and 37, the gel loaded wire extends along substantially the entire longitudinal length of the tubular element. Advantageously, this creates a channel of the length of the tubular element of the aerosol channel.

Fig. 38 also shows a tubular element 500 comprising a wire 125 loaded with gel. In this example, there are three second tubular elements 304 and the gel loaded wire 125 is located between the three second tubular elements and between the second tubular elements and the inner surface of the wrap 110.

Fig. 39 shows a tubular element comprising a gel loaded wire 125, wherein the tubular element 500 comprises more than one gel 124. In this example, gel-loaded wire 125 is evenly split between gel-loaded wire 125A having one gel 124 and gel-loaded wire 125B having another gel 124.

All scientific and technical terms used herein have the meanings commonly used in the art, unless otherwise indicated. The definitions provided herein are to facilitate understanding of certain terms used frequently herein.

As used in this specification and the appended claims, the singular forms "a," "an," and "the" encompass embodiments having plural referents, unless the content clearly dictates otherwise.

As used in this specification and the appended claims, the term "or" is generally employed in its sense including "and/or" unless the content clearly dictates otherwise.

As used herein, "having," "including," "comprising," and the like are used in their open sense and generally mean "including (but not limited to)". It should be understood that "consisting essentially of … …", "consisting of … …", etc. are included in "comprising", etc.

The words "preferred" and "preferably" refer to embodiments of the invention that may provide certain benefits in certain circumstances. However, other embodiments may be preferred under the same or other circumstances. Furthermore, recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure including the claims.

Any reference herein to directions such as "top," "bottom," "left," "right," "upper," "lower," and other directions or orientations described herein for clarity and brevity are not intended to limit the actual device or system. The devices and systems described herein may be used in a variety of directions and orientations.

The embodiments illustrated above are not limiting. Other embodiments consistent with the above-described embodiments will be apparent to those skilled in the art.

Examples

1. A tubular element, wherein the tubular element comprises a first longitudinal channel and further comprises a gel loaded wire; the gel comprises an active agent.

2. The tubular member of embodiment 1, wherein the tubular member comprises a plurality of gel-loaded wires.

3. The tubular element of embodiment 1 or 2, wherein the tubular element comprises more than one gel.

4. The tubular element of embodiment 2, wherein the gel-loaded wire comprises a different gel than the gel in another gel-loaded wire.

5. The tubular element of the preceding embodiment, wherein the active agent is a flavor, or a drug, or nicotine, or an aerosol former, or a combination of any or all of the following: flavors, medicaments, aerosol formers or nicotine.

6. The tubular element of any preceding embodiment, wherein the tubular element further comprises a susceptor that facilitates heat transfer.

7. The tubular element of any preceding embodiment, wherein a wrap is included.

8. The tubular element of embodiment 7, wherein the wrap comprises susceptors for aiding in heat transfer.

9. The tubular element of any one of embodiments 7 or 8, wherein the wrap is stiff.

10. The tubular element of any one of embodiments 7, 8, or 9, wherein the wrap is waterproof.

11. The tubular element of any preceding embodiment, wherein the tubular element further comprises a porous medium loaded with gel.

12. The tubular element of any preceding embodiment, wherein the tubular element further comprises a second tubular element positioned longitudinally within the first longitudinal channel.

13. An article comprising the tubular element according to any one of embodiments 1 to 12.

14. A method of manufacturing a tubular element,

the tubular element comprises:

the method comprises the following steps:

15. A method of manufacturing the tubular element of embodiment 14, further comprising the steps of: a plurality of gel loaded wires are dispensed from a catheter within the mandrel.

Claims

1. A tubular element for use with an aerosol-generating article, the tubular element having a longitudinal length and comprising a first wrapper forming a first longitudinal passageway; the tubular member further comprises a plurality of gel loaded porous wires, wherein the plurality of gel loaded porous wires extend longitudinally parallel to the longitudinal length of the tubular member; the gel comprises an aerosol former and an active agent; wherein the aerosol former comprises 60% to 95% by weight of glycerin, and wherein the active agent comprises nicotine.

2. The tubular element of claim 1, wherein the tubular element further comprises at least one second tubular element comprising a second wrap, the at least one second tubular element being positioned longitudinally within the first longitudinal passageway; and wherein the plurality of gel-loaded porous wires are located between the at least one second tubular element and the inner surface of the first wrapper.

3. The tubular element of claim 1, wherein the first wrapper comprises paper.

4. The tubular element of claim 1, wherein the first wrap is hydrophobic.

5. The tubular element of claim 4, wherein the first wrap comprises hydrophobic groups covalently bonded to an outer side of the first wrap.

6. The tubular element according to claim 4 or 5, wherein the first wrap comprises hydrophobic groups on the inner side of the first wrap.

7. The tubular element according to any one of claims 1 to 5, wherein the tubular element comprises a distal end and a proximal end, and wherein an end plug is positioned at the distal end of the tubular element.

8. The tubular element of claim 7, wherein the end plug of the tubular element is fluid impermeable.

9. The tubular element according to claim 1 or 2, wherein the first wrap is stiff.

10. The tubular element of any one of claims 1, 3 to 5, wherein the tubular element further comprises a susceptor.

11. The tubular element of claim 10, wherein the susceptor is positioned longitudinally within the tubular element.

12. The tubular element of claim 10, wherein the susceptor is positioned adjacent to the plurality of gel-loaded porous wires.

13. The tubular element of claim 11, wherein the susceptor is positioned adjacent to the plurality of gel-loaded porous wires.

14. The tubular element according to any one of claims 1 to 5, wherein the plurality of gel-loaded porous wires extend along the longitudinal length of the tubular element.

15. The tubular element of any one of claims 1-5, wherein the plurality of gel-loaded porous threads comprises cotton.

16. The tubular element according to any one of claims 1 to 5, wherein the plurality of gel loaded porous wires comprises paper or cellulose acetate tow.